JP2012153108A - Foam resin molding block, foam molding machine, its operation method, and light-weight bank structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To suppress variations of the distribution of internal density, in a foam resin molding block of a rectangular parallelepiped shape used as light-weight bank in civil engineering.SOLUTION: In the foam resin molding block 10 of the rectangular parallelepiped shape which is used in the light-weight bank in the civil engineering and has a longitudinal length a, a lateral length b, and a height c, when the density of the block is α(kg/m), the density β of an×bn×cn pieces of divided blocks which is obtained by an-dividing the foam resin molding block 10 in the direction of the longitudinal length a, by bn-dividing it in the direction of the lateral length b, and by cn-dividing it in the direction of the height c (here, an, bn≥3, cn≥1) is brought into a range of (1±0.0X)α(kg/m) as a whole.

Description

  The present invention relates to a rectangular parallelepiped foamed resin molding block used as a lightweight embankment in civil engineering work, a foam molding machine therefor, and a method for operating the foam molding machine. Moreover, it is related with the lightweight banking structure which used the foamed resin molding block as a lightweight banking.

  As a method of civil engineering work, especially when performing embankment on soft ground or landslide land, a rectangular resin foam block such as expanded polystyrene (EPS) block is used as a lightweight embankment material. The lightweight embankment method used is known. This construction method has excellent effects in reducing the cost of ground improvement, shortening the construction period, and improving earthquake resistance. FIG. 11 shows an example of a single-bank type lightweight banking structure constructed by a lightweight banking method. An H-shaped steel 2 is erected on the slope side of an existing ground where an existing road 1 is formed at the top. The EPS blocks 4 are stacked as a lightweight embankment material between the steel 2 and the supporting ground 3 to form a light embankment layer having a predetermined height. After that, the necessary reinforcement 5 is placed on the stacked EPS block 4 and concrete is cast to a predetermined thickness to construct a concrete floor slab 6. The tip of the anchor 7 embedded and fixed on the supporting ground 3 is connected to the concrete floor. Connect to plate 6 to improve stabilization. And the process of forming the road layer by the roadbed 8, the asphalt pavement 9 etc. on the concrete floor slab 6 like a normal civil engineering work is performed. In addition to the concrete slab 6, an intermediate concrete slab may be provided. In such a lightweight embankment method, a large number of cuboid-shaped foamed resin molding blocks are arranged in the left-right direction and the up-down direction to construct a lightweight embankment layer. In order to connect the blocks to each other and stabilize them, a binding tool as described in Patent Document 1 is used.

  The rectangular parallelepiped foamed resin molding block used in the above civil engineering work is usually filled with foamed particles obtained by prefoaming expandable resin particles in a molded product chamber of a foam molding machine. The molded product chamber is molded by introducing steam from a steam chamber formed around it into the molded product chamber so that the foamed particles filled in the molded product chamber are fused together with the foam.

  It is desirable that the molded foamed resin molding block has a foaming factor, a thermal conductivity, etc. as uniform as possible throughout the block. For this purpose, a foam molding machine has been proposed in which the opening ratio and opening area of the steam supply holes for supplying steam into the molded product chamber of the foam mold are adjusted for each molding surface. 2 and Patent Document 3. In Patent Document 2, in a molding die for forming a foamed polystyrene block molded body, the opening ratio of the steam supply holes of the hot plate constituting the molded product chamber (molded product chamber) is formed densely in the central portion of the hot plate. In addition, the peripheral portion is formed roughly. Moreover, in the molding die for foamed resin molding block manufacturing described in Patent Document 3, in the molding die for manufacturing the foaming resin molding block having a rectangular parallelepiped shape surrounded by six surfaces, the front molding surface having the maximum area and The sum of the steam hole opening areas of the back molding surface is set to be smaller than the sum of the steam hole opening areas of the other four side molding surfaces.

JP 2005-16036 A JP-A-8-20035 Japanese Patent No. 4176460

  As described above, by adjusting the opening ratio and opening area of the steam supply hole to the molded product chamber of the foam molding machine for each molding surface, the foaming resin molding in which the expansion factor, thermal conductivity, etc. are almost uniform over the entire block. It is possible to foam the block. However, since the form of the foam molding machine is a form in which steam is supplied from the surrounding molding surface to the pre-expanded particles filled in the mold chamber, the pre-foaming located at the center of the mold chamber It is difficult to impart equal foaming conditions by steam heat to the pre-foamed particles located in the vicinity of the particles and the molding surface, and in the foamed resin molding block after foam molding, the density at the center is high ( It is not possible to completely avoid the fact that the density is small (the foaming factor is large) compared to the peripheral wall surface region. In particular, the conventional foam molding machine has a configuration in which one steam blowing pipe is connected to each steam chamber, and the amount and pressure of steam blown into the steam chamber cannot be adjusted in the steam chamber. It is extremely difficult to eliminate the density difference between the central portion and the peripheral wall surface area or to make the density difference within a predetermined range.

  Also, when foam molding is continuously performed under the same conditions, even if the density difference between the center portion of the foamed resin molding block to be molded and the peripheral wall surface area is within a predetermined range desired by the user In addition, in the process, the steam holes formed on the molding surface are partially clogged, and the density difference between the center portion and the peripheral wall surface region may be out of the predetermined range. In the conventional foam molding machine, when the operator knows that such a situation has occurred, the molding operation is interrupted and the steam holes are cleaned, etc. There are still points to be improved.

  Furthermore, when performing a lightweight embankment method as described in Patent Document 1 using a rectangular parallelepiped foamed resin molded block having a density difference of more than a specified value at the center and the peripheral wall surface region, four rounds of the foamed resin molded block It cannot be avoided that there is a difference in the amount of deformation (sinking amount) in the vertical direction due to the overload between the wall surface region and the center region of the upper and lower surfaces. When the foamed resin molding blocks are stacked up and down in multiple stages, if the four wall surface regions having a large deformation amount are stacked so as to be continuous in the vertical direction, the center region between the upper and lower surfaces and the four wall surface regions are There is a possibility that a non-negligible size difference may occur in the amount of sedimentation. In order to avoid this, the corners of adjacent foamed resin molding blocks are stabilized by hitting a fastening tool as described in Patent Document 1, and for example, the upper and lower surfaces of the lower foamed resin molding block. It is necessary to pile up the four foamed resin molding blocks located in the upper part of the center area in a central area so that the corners of the four foamed resin molding blocks are located in multiple stages. Need.

  The object of the present invention is to eliminate the inconvenience of a rectangular solid foamed resin molded block used as a lightweight embankment in civil engineering work as described above, and more specifically, one foamed resin molded block. It is a first object to provide a foamed resin molded block with extremely small variation in internal density distribution. Another object of the present invention is to provide a foam molding machine for foam molding such a foamed resin molding block. Furthermore, it is a third object to provide a method for operating a foam molding machine for continuously molding a foam resin molding block with extremely small variation in internal density distribution using the above-described foam molding machine. Moreover, let it be the 4th subject to provide the lightweight banking structure which used said foamed resin molding block as a lightweight banking.

The foamed resin molding block according to the present invention is used as a lightweight embankment in civil engineering work, and is a rectangular parallelepiped foam having a longitudinal length a, a lateral length b, a height c, and a surface having a longitudinal length a × lateral length b being the maximum surface. When the density of the foamed resin molded block is α (kg / m ³ ), the foamed resin molded block is divided into an equal portion in the longitudinal length a direction and an equal portion bn in the lateral length b direction. , The density β of the an × bn × cn divided blocks obtained by dividing cn in the height c direction (where an, bn ≧ 3, cn ≧ 1) is (1 ± 0.06) α (kg / M ³ ).

In the above foamed resin molded block, the density β of each divided block divided into an × bn × cn is within the range of (1 ± 0.06) α (kg / m ³ ), and the density inside the block The distribution variation is extremely small. Therefore, when this foamed resin molded block is used as a lightweight embankment, the amount of vertical deformation (sinking amount) due to the overload is substantially uniform over the entire upper and lower surfaces. Therefore, when stacking as a lightweight embankment in multiple stages, even if the stack is done without paying sufficient attention to the position of the foamed resin molding blocks placed above and below, the variation in the amount of sedimentation in the horizontal plane as a light embankment is small. Become. Moreover, since the attitude | position when it piles up as a result becomes stable, it becomes possible to abbreviate | omit the operation | work which binds adjacent foamed resin molding blocks using the binding tool as described in patent document 1. FIG. Therefore, construction as a lightweight embankment method becomes extremely easy.

  In the foamed resin molded block according to the present invention, an, bn ≧ 3, and cn ≧ 1 are the most common block in the vertical length a direction × horizontal length b, that is, the loading surface during construction. By dividing the wide surface into at least three equal parts by nine equal parts, it is possible to obtain a distribution of the internal density in an unbiased state to the extent that there is no hindrance when actually used as a lightweight embankment. Of course, if a larger value is selected as the values of an, bn, and cn, a foamed resin molded block with less variation in internal density is obtained. Appropriate values of an, bn, and cn may be selected according to the environment of the construction site where the foamed resin molding block is used as a lightweight embankment. Note that the values of an, bn, and cn may be the same or different. However, in the construction site, it may be used in a posture in which the surface of the maximum surface length a direction × horizontal length b is not used as the loading surface of the overload, so the values of an, bn, and cn are equal to 3 or more. A value is a more preferable aspect.

  In the foamed resin molding block according to the present invention, the density β is set to the range of (1 ± 0.06) α. The experience exceeds that when the density β is piled up in multiple stages as a lightweight embankment. This is because the variation in deformation may become a size that cannot be ignored.

In the foamed resin molding block according to the present invention, preferably, the α is 10 (kg / m ³ ) or more and 40 (kg / m ³ ) or less. Experience has shown that foamed resin molded blocks with an α of less than 10 (kg / m ³ ) have a resistance that is too small for lightweight embankments in civil engineering work and cannot be ignored due to temporal or temporary local loads. (Sinking) may occur. Moreover, the foamed resin molding block in which α exceeds 40 (kg / m ³ ) is too heavy as a lightweight embankment in civil engineering work, and may not perform its original function as a lightweight embankment.

  In the foamed resin molding block according to the present invention, preferably, the foamed resin molding block has a longitudinal length a of 1500 mm or more, a lateral length b of 700 mm or more, and a height c of 300 mm or more. From experience, foamed resin molding blocks with smaller dimensions have a variation in internal density that would be a hindrance when used as a lightweight embankment in civil engineering work, even when foamed by conventional methods on conventional foam molding machines. It is unlikely to occur. Although the above values do not have a critical meaning, the present inventors have a foamed resin molded block having a size such that the vertical length a is approximately 1500 mm, the horizontal length b is 700 mm, and the height c is greater than 300 mm. If the conventional foam molding machine is used for foam molding by conventional methods, it has been experienced that foamed resin molded blocks with variations in internal density that would interfere with the use of lightweight embankments in civil engineering work may be molded. ing.

  The foamed resin molding block according to the present invention may be formed by extrusion foaming, and the pre-foamed particles obtained by pre-foaming the foamable resin particles are placed in a mold in a molding product chamber of a foam molding machine having a molding product chamber and a steam chamber. It may be a foamed resin molded block obtained by foam molding. The resin is preferably a styrene resin, but may be an olefin resin such as polypropylene, or a resin such as a mixture or copolymer of olefin and styrene resin.

  The present invention is a foam molding machine used for in-mold foam molding of the above-mentioned foamed resin molding block, and has at least a molded product chamber and a steam chamber, and a plurality of steam blows into the steam chamber. Also disclosed is a foam molding machine characterized in that a pipe is connected and a control means capable of controlling the steam pressure and the steam flow rate is provided for each steam blowing pipe.

  In the foam molding machine according to the present invention, a plurality of steam blowing pipes are connected to one steam chamber, and control means capable of controlling the steam pressure and the flow rate of steam supplied from the steam blowing pipes are provided. More preferably, each of the plurality of steam blowing pipes is provided with control means capable of controlling the steam pressure and the steam flow rate.

  In the foam molding machine according to the present invention, an appropriate amount of properly regulated steam can be fed from different locations in the steam chamber at the time of foam molding, and a foamed resin molding block having no variation in density distribution is molded. It becomes easy. In particular, in a foam molding machine provided with a control means capable of controlling the steam pressure and the steam flow rate in each of a plurality of steam blow-in pipes, two or more types having different conditions in one steam chamber at the time of foam molding. As a result, it becomes possible to supply steam at different temperatures or pressures to different regions in the molded article chamber. As a result, the actual molded product is divided into an × bn × cn divided blocks, each density β is measured, the tendency of the density distribution is grasped by using the variation degree as a database, and the variation of the density distribution is determined. By repeating the operation of appropriately adjusting the control means so as to correct, the density β of the above-mentioned an × bn × cn divided blocks is all within the range of (1 ± 0.06) α. Can be reliably molded. In addition to controlling the steam pressure and the steam flow rate by the control means, the number of the steam blowing pipes and the mounting position of the steam blowing pipe and the steam hole formed on the molding surface of the molded product chamber based on the obtained database. By adjusting the opening ratio and the opening area, it is possible to form a foamed resin molding block with less variation in internal density.

  In the foam molding machine according to the present invention, a partition plate is provided in the steam chamber so that steam blown from two or more steam blow pipes connected to one steam chamber is not mixed in the steam chamber. It can also be divided into more than one block.

  By using the above-described foam molding machine and performing processing such as adjusting the control means as described above, the density β of the an × bn × cn divided blocks is all (1 ± 0.06) α. A foamed resin molding block within the range is molded. However, if a large number of foamed resin molding blocks are continuously molded under the same conditions, it is inevitable that partial clogging occurs in the vapor holes formed on the molding surface of the molded product chamber, As a result, the supply condition of the steam into the molded product chamber changes, and the internal density distribution of the foamed resin molding block changes, and the density β of some divided blocks is outside the range of (1 ± 0.06) α. Will happen. The present invention also discloses a method for operating the foam molding machine, which can avoid the disadvantages.

That is, the operation method of the foam molding machine according to the present invention is a longitudinal length a, a lateral length b, and a height c that are used as a lightweight embankment in civil engineering using the foam molding machine according to the present invention, and the longitudinal length a × the lateral length. An operation method of a foam molding machine for continuously producing a rectangular solid foam resin molding block having a density α (kg / m ³ ) in which the surface of b is the maximum surface, and the foam resin molding block for one batch After sampling, an appropriate foamed resin molded block is sampled, and the sampled foamed resin molded block is divided into an equal portion in the longitudinal length a direction, an equal portion in the lateral length b direction, and an equal portion in the height c direction. (Where, an, bn ≧ 3, cn ≧ 1), and the density β (kg / m ³ ) of each of the obtained an × bn × cn divided blocks is measured, and the density β is determined as the density α (kg / ^{m 3)} the ratio Then, the vapor pressure and vapor flow blown into the vapor chamber are adjusted by using the control means provided for each vapor blowing pipe so that each density β approaches the density α, and then the foamed resin molding of the next batch is performed. The manufacturing operation of the block is started. Here, the values of an, bn, and cn may be the same or different on condition that the conditions of an, bn ≧ 3, and cn ≧ 1 are satisfied.

  By adopting the above operation method, it becomes possible to feed back the previous molding result to the current molding, and it is possible to more easily and more reliably mold a high-quality foamed resin molding block with no variation in internal density distribution. It becomes like this.

  The present invention further discloses a lightweight embankment structure using the above-described foamed resin molded block as a lightweight embankment. More specifically, a light-weight embankment constructed by stacking a plurality of the above-mentioned foamed resin molding blocks on a support ground in multiple stages, and construction on the light-weight embankment directly or via an embankment layer It is a lightweight embankment structure characterized by comprising at least a ground structure such as a road or the like.

  The light weight embankment structure may be a single embankment type light weight embankment structure in which one side surface of the light weight embankment is a vertical surface, and both sides of the light weight embankment are vertical surfaces. An embankment type lightweight embankment structure may be used. Further, one side or both side surfaces of the light weight embankment may be a slope embankment type light weight embankment structure having an inclined surface.

  In any lightweight embankment structure, the lightweight embankment part is formed by stacking the foamed resin molding blocks according to the present invention, and as described above, when being stacked in multiple stages as a lightweight embankment, they are arranged vertically. Even if they are stacked without paying sufficient attention to the location of the foamed resin molding blocks, they will sink in the horizontal plane as a lightweight embankment when an overload is applied from the ground structure side such as a road constructed on it. The amount is small, and a stable lightweight embankment structure without uneven settlement is obtained.

  According to the present invention, there is provided a rectangular parallelepiped foamed resin molded block that is used as a lightweight embankment in civil engineering work with extremely small variation in internal density distribution. In addition, a foam molding machine for foam molding such a foamed resin molding block and an operation method thereof are provided. Furthermore, there is provided a light weight embankment structure using the foamed resin molded block as a light weight embankment, which is easy to construct and does not cause unequal settlement due to an overload, etc.

The figure for demonstrating an example of the foaming resin molding block by this invention. The perspective view for demonstrating an example of the foam molding machine by this invention. The top view and side view for demonstrating the foam molding machine shown in FIG. The figure corresponded in FIG. 3 for demonstrating the other example of the foam molding machine by this invention. The figure corresponded in FIG. 3 for demonstrating the further another example of the foam molding machine by this invention. The figure corresponded in FIG. 3 for demonstrating the further another example of the foam molding machine by this invention. The figure which shows the foaming resin molding block used for the experiment for demonstrating the effectiveness of the foaming resin molding block by this invention. The figure explaining an example of the lightweight banking structure using the foamed resin molding block by this invention as a lightweight banking. The figure explaining other of the lightweight banking structure which used the foaming resin molding block by this invention as a lightweight banking. The figure explaining the further another example of the lightweight banking structure using the foamed resin molding block by this invention as a lightweight banking. The figure for demonstrating an example of the lightweight banking structure constructed | assembled by the lightweight banking construction method using a rectangular parallelepiped foamed resin molding block as a lightweight banking material.

Hereinafter, the present invention will be described based on embodiments.
FIG. 1 is a view for explaining an example of a foamed resin molded block according to the present invention. FIG. 1 (a) is a block in a foamed state, and FIG. 1 (b) is a block in a state of being divided into a plurality of blocks. Is shown. The foamed resin molded block 10 is used as a lightweight embankment in civil engineering work, and is a rectangular parallelepiped shaped foamed resin molded block having a longitudinal length a, a lateral length b, and a height c. Although not limited, in this example, the foamed resin molding block 10 is obtained by in-mold foam molding of pre-expanded particles of a styrene resin. The vertical length a, the horizontal length b, and the height c are not particularly limited, but in this example, the vertical length a is about 1000 mm, the horizontal length b is about 2000 mm, and the height c is about 500 mm. The overall density (apparent density) α of the foamed resin molding block 10 is, for example, 20 kg / m ³ .

In addition, as shown in Table 1, the foamed resin molding block used as a lightweight embankment in civil engineering work is usually graded in four stages according to the density, and the allowable compressive strength is determined accordingly. Therefore, the foamed resin molding block 10 shown in FIG. 1 is called D-20, and an allowable compressive strength of 50 kN / m ² is required.

As described above, in the foamed resin molded product, in particular, the in-mold foamed molded product, it is inevitable that the internal density varies due to the relationship of the supply state of the steam to the pre-expanded particles filled in the molded product chamber. That is, it cannot be completely avoided that the density is high in the central portion and the density is lower than that in the surface portion. Therefore, when foam molding is performed by a conventional molding method, even when the overall apparent density called D-20 is a block of 20 kg / m ³ , when the internal density of the block is measured, the center portion is 22 kg / m ^3. It is possible that the surface portion is about 18 kg / m ³ . In such a case, when the allowable compressive strength is designed at a limit of 50 kN / m ² , the compressive strength of the portion having a density of 18 kg / m ³ is insufficient. Therefore, in practice, a portion with sufficient strength is responsible for the load of a portion with insufficient strength. Therefore, depending on the ratio of the portion with sufficient strength and the portion with insufficient strength, a load is also applied to the portion with sufficient strength.

The foamed resin molding block 10 according to the present invention is designed to be able to handle the above-mentioned load uniformly, assuming that the variation in internal density is extremely small. That is, according to the present invention, when the allowable compressive strength of the design required when using as a lightweight fill is 50 kN / m ^2, actually using the product of D-20 allowable compressive strength of 50 kN / m ² Even so, the foamed resin molded block 10 in which problems such as uneven settlement do not occur after construction is provided.

  In the foamed resin molding block 10 according to the present invention, it is verified as follows that the degree of variation in internal density is very small. That is, one or one or more foamed resin molding blocks 10 are extracted as a sample from a group of many foamed resin molding blocks molded using a foam molding machine described later. As shown in FIG. 1B, the extracted foamed resin molding block 10 shown in FIG. 1A is divided into an equal part in the longitudinal length a direction, a bn equivalent part in the lateral length b direction, and a cn part in the height c direction. Divide equally to obtain an × bn × cn divided blocks 10p. In the example shown in FIG. 1, an is 5, bn is 8, and cn is 5, which is divided into 5 × 8 × 5 = 200 (pieces) divided blocks 10p. Each divided block 10p is a rectangular parallelepiped block of 240 mm × 450 mm × 180 mm.

  As described above, an, bn, and cn need only be values of an, bn ≧ 3, and cn ≧ 1, and they may be different values as shown in the figure, and the same value (for example, An, bn, and cn may all be 3).

The density β of each divided block 10p thus divided is measured, and the value is compared with the density α of the entire foamed resin molded block 10. When the density β of all the divided blocks 10p is in the range of (1 ± 0.06) α (kg / m ³ ), the foamed resin molded block 10 is a foamed resin molded block within the scope of the present invention. 10 is assumed. In this example, resin foam block 10 overall density of α is 20 kg / ^{m 3,} if all the divided blocks density of 10p beta is in the range of 21.2~18.8kg / ^{m 3} is present The foamed resin molding block 10 is within the scope of the invention.

When the 200 divided blocks 10p include those having a density β outside the range of (1 ± 0.06) α (kg / m ³ ), the foamed resin molded block 10 is within the scope of the present invention. It will be out of the way.

  When a foamed resin molding block is continuously molded using a foam molding machine, it is normal that the partial clogging of the vapor holes gradually increases every time the molding cycle is repeated. The distribution of the internal density of the molding block also changes gradually. Initially, even if the supply balance of steam was set so that the foamed resin molding block 10 satisfying the conditions of the present invention was obtained, as the molding was repeated with 100 or 200, it was caused by clogging of the steam holes. Thus, it is inevitable that the supply balance of the steam will change from the initial setting conditions, and eventually a foamed resin molding block that does not satisfy the above-described conditions of the present invention will be molded. Therefore, after molding a certain number of samples, the final molded product is sampled, and the division and density β are measured as described above. If the result satisfies the conditions of the invention, the foamed product is molded there. It can be estimated that the resin molding block 10 is within the scope of the present invention.

  Furthermore, after molding a certain number of samples, the final molded product is sampled, and the above division and density β are measured. If the result does not satisfy the conditions of the invention, Since the foamed resin molding block is out of the scope of the present invention, the foamed resin molding block outside the range is excluded, the vapor hole of the molding machine is cleaned, the molding conditions are returned to the initial, and the foamed resin is again formed. Molding the molding block.

In the foam molding machine, the density β of the divided block 10p located at any position among the many divided blocks 10p is out of the range of (1 ± 0.06) α (kg / m ³ ). Foamed resin molding that is stored in the foam molding machine based on the data, such as how easy it is, how far it is detached, and how many pieces it is likely to cause such a detachment phenomenon Understand the changing tendency of density distribution in blocks. Based on this, by controlling the supply conditions of the steam into the molded product chamber, the foamed resin molding block 10 within the scope of the present invention can be foam-molded.

  Next, a foam molding machine suitable for manufacturing the foamed resin molding block according to the present invention and its operating method will be described.

  2 and 3 show an example of a foam molding machine. In this example, the foam molding machine A1 includes a first mold 20 and a second mold 30. FIG. 2A shows a state in which two molds are opened, and FIG. 2B shows a state in which the mold is closed. Is shown. The first mold 20 has a molded product chamber 21. The molded product chamber 21 has a rectangular parallelepiped shape defined by a bottom heat plate 22 having a large number of steam holes (not shown) and four side heat plates 23. The outside of the molded product chamber 21 is a vapor chamber 27 defined by a top plate 24, a bottom plate 25, and four side plates 26.

  The molded product chamber 21 is filled with pre-expanded particles from a supply device (not shown). Further, a regulated amount of high-temperature steam is supplied into the steam chamber 27 via a pressure regulating valve 40 from a high-temperature high-pressure steam generation source (not shown). In the foam molding machine A1 shown in FIGS. 2 and 3, the steam blowing pipe ahead of the pressure regulating valve 40 is branched into two, and steam is supplied into the steam chamber 27 from two places. Dispersion plates 28 are arranged at positions facing the respective steam blowing pipes in the steam chamber 27, and the steam supplied into the steam chamber 27 collides with the dispersion plate 28, whereby the bottom heat plate 22. Disperse in the direction along. Although it can be omitted, a partition plate 29 of an appropriate size can be provided between the two dispersion plates 28 so that the steam supplied from each steam blowing pipe is not mixed in the steam chamber 27. .

  The second mold 30 is of a size that can cover the molded product chamber 21 formed in the first mold 20, and includes a sealed hot plate 31 having a number of vapor holes (not shown), and the sealed hot plate. The box body 32 is formed so as to cover the back side of 31, and the inside of the box body 32 is a vapor chamber 33. A regulated amount of high-temperature steam is also supplied into the steam chamber 33 via a pressure regulating valve 41 from a high-temperature and high-pressure steam generation source (not shown). Also in the second mold 30, the steam blowing pipe ahead of the pressure regulating valve 41 is branched into two, and steam is supplied into the steam chamber 33 from two places. Dispersion plates 34 are also arranged at positions facing the steam supply port in the steam chamber 33, and the steam supplied into the steam chamber 33 collides with the dispersion plate 34, thereby causing the sealing heat plate 31 to Disperse along the direction. Although it can be omitted, a partition plate 35 of an appropriate size can be provided between the two dispersion plates 34 so that the steam supplied from each steam blowing pipe is not mixed in the steam chamber 33. .

  Although not shown, the foam molding machine A1 includes control means including control means capable of controlling the steam pressure and the steam flow rate in each of the steam blowing pipes, and adjusting and adjusting the steam flow rate through the pressure regulating valves 40 and 41. The opening degree of the pressure valves 40 and 41 is adjusted.

  FIG. 4 shows another example of the foam molding machine. In the foam molding machine A2, the steam blowing pipes are branched into four at the tip of the pressure regulating valves 40 and 41, and face each steam blowing pipe. This is different from the foam molding machine A1 shown in FIG. 2 and FIG. 3 in that four dispersion plates 28 and 34 are provided at the positions. Other configurations are the same as those of the foam molding machine A1, and the same reference numerals are given and description thereof is omitted. In FIG. 4, the partition plates 29 and 35 provided as necessary between the respective dispersion plates 28 and 34 are omitted.

  FIG. 5 shows still another example of the foam molding machine. This foam molding machine A3 has four steam supply pipes from a high-temperature and high-pressure steam generation source (not shown), and each steam supply pipe has a pressure regulating valve. It differs from the foam molding machine A2 shown in FIG. 4 in that 40a to 40d and 41a to 41d are provided. Other configurations are the same as those of the foam molding machine A2, and the same reference numerals are given and the description thereof is omitted. Also in FIG. 5, the partition plates 29 and 35 provided as necessary between the respective dispersion plates 28 and 34 are omitted.

  Although not shown, the foam molding machine A3 includes control means including control means capable of controlling the steam pressure and the steam flow rate in each of the steam blowing pipes, the pressure regulating valves 40a to 40d, and the pressure regulating valves 41a to 41a. Adjustment of the flow rate of steam flowing through 41d and adjustment of the opening degree of these valves are performed.

  FIG. 6 shows still another example of the foam molding machine. In this foam molding machine A4, the four steam blowing pipes on the steam chamber 27 side are further branched into three on the downstream side of the pressure regulating valves 40a to 40d. In addition, the steam chamber 27 opens, and the four steam blowing pipes on the steam chamber 33 side further branch into three on the downstream side of the pressure regulating valves 41a to 41d and open into the steam chamber 33. This is different from the foam molding machine A3 shown in FIG. Other configurations are the same as those of the foam molding machine A3, and the same reference numerals are given and the description thereof is omitted. Also in FIG. 6, the partition plates 29 and 35 provided between the respective dispersion plates 28 and 34 as needed are omitted.

  In any of the foam molding machines A1 to A4, when molding the foamed resin molding block 10, a predetermined amount of pre-expanded particles is filled into the molded product chamber 21 of the first mold 20 in an open state, After clamping the mold, steam of a predetermined condition is supplied to both the steam chambers 27 and 33 to foam and fuse the pre-expanded particles. Thereafter, the desired foamed resin molded block 10 is obtained by opening the mold. This molding method is the same as the conventional one.

  The obtained foamed resin molding block 10 is divided into a plurality of parts as described with reference to FIG. 1 to obtain a large number of divided blocks 10p. And each density is measured. Thereby, the information regarding the variation in the internal density of the molded foamed resin molding block 10 is obtained. Based on the obtained information, the steam amount and the steam pressure supplied from the steam blowing pipes to both the steam chambers 27 and 33 are controlled by the pressure regulating valves 40 and 41 and so that the variation is as small as possible. Adjustment is made by appropriately controlling the steam flow rate and the like on the upstream side. By repeating this procedure several times, it is possible to obtain the foamed resin molding block 10 in which the variation in the internal density distribution is, for example, ± 6% or less.

  In the foam molding machines A1 to A4 illustrated and exemplified, the more the number of steam blowing pipes to both the steam chambers 27 and 33, the more precisely the steam blowing conditions into the molded product chamber 21 can be controlled. Thus, the foamed resin molded block 10 having a smaller variation in internal density distribution can be obtained. Considering the degree of uniformity of the internal density distribution required for the foamed resin molding block 10 and the cost for the foam molding machine and its operation, the foam molding machines A1 to A4 having an appropriate number of steam blowing pipes are used. You can do it.

  Moreover, in any foam molding machine, clogging of the steam holes formed in both the steam chambers 27 and 33 cannot be avoided with time, and the steam supply conditions change over time. To do. Therefore, even if the desired vapor supply conditions are obtained as described above and the desired foamed resin molded block 10 is molded, the foamed resin molded block 10 gradually deviating from the initial conditions is gradually molded.

For that purpose, after manufacturing a batch of foamed resin molding blocks of about 100 or 200, an appropriate foamed resin molding block is sampled from the block, and the sampled foamed resin molding block is longitudinally long as described above. Divide into an equal part in the a direction, bn equally in the horizontal length b direction, and cn equal to the height c direction, and measure the density β (kg / m ³ ) for each of the obtained an × bn × cn divided blocks. Then, the density β is compared with the initially set density α (kg / m ³ ), and the control means provided in each steam blowing pipe is used so that each density β approaches the density α. It is possible to adjust the vapor pressure and vapor flow blown into the chambers 27 and 33 and then adopt an operation method in which the production operation of the foamed resin molding block of the next batch is started. Umate is desirable.

  At that time, by arranging the partition plates 29 and 35 between the respective dispersion plates 28 and 34 in the respective steam chambers 27 and 33, the steam supplied from the respective steam blowing pipes is mixed in the respective steam chambers 27 and 33. Therefore, it is easy to obtain the foamed resin molded block 10 that matches the initial conditions.

Next, the foamed resin molding block according to the present invention will be described with reference to examples and comparative examples. FIG. 7 shows a foamed resin molding block used in Examples and Comparative Examples. ^Three rectangular parallelepiped foamed resin molding blocks X, Y, and Z having a density α of 19.7 kg / m ³ were prepared. In addition, for the molding of the foamed resin molding blocks X, Y, and Z, by using the same foaming machine and adjusting the amount, temperature, and pressure of steam supplied into the steam chamber, as shown in Table 2 below, The variation in internal density distribution was varied.

Specifically, the foamed resin molding block X is a foam molding machine of the form shown in FIG. 2 and FIG. 3 and does not include the partition plate 29. The molding condition is a vapor pressure of 1 kg / cm ^2. Molding was performed at a heating time of 20 seconds and a mold temperature of 120 degrees. The foamed resin molding block Y was molded using the same foam molding machine, with molding conditions of a vapor pressure of 0.7 kg / cm ² , a heating time of 35 seconds, and a mold temperature of 115 degrees. The foamed resin molding block Z is the same as the foam molding machine of the form shown in FIG. 6, that is, the overall shape is the same as that of the foam molding machine that molded the foamed resin molding block X. Using a foam molding machine that is further branched into three on the downstream side of the pressure valves 40a to 40d and 41a to 41d and opened in the steam chamber, the molding conditions are set to a vapor pressure of 0. 5 kg / cm ^2, pressure regulating valve 40b, the 41b 0.6kg / cm ^2, pressure regulating valve 40c, 0.7kg / cm ² at 41c, regulating valve 40d, the 41d 0.5kg / cm ^2, heating time 40 Second, the mold temperature was 115 degrees.

  Each foamed resin molded block was divided into nine equal parts on the widest side, and numbers A to I were assigned to the respective divided blocks as shown in FIG. That is, all the foamed resin molding blocks X, Y, and Z are divided into three equal parts in the longitudinal length a direction, three equal parts in the lateral length b direction, and one equal part in the height c direction, thereby dividing the nine divided blocks A˜ I was obtained. Then, the density β of each divided block was measured. The results are shown in Table 2.

(1) of all the divided blocks in the block X, the maximum density of the block E 22.0kg / ^{m 3,} the minimum density was 18.5 kg / ^{m 3} of the block C, the overall density at the total split blocks maximum variation from 19.7 kg / ^{m 3} are + 2.3kg / ^{m 3,} that is, 10%.

(2) of all the divided blocks of the block Y, the maximum density is 21.5 kg / ^{m 3} of the block E, the minimum density block A, a 19.0 kg / ^{m 3} and C, of among all the divided blocks maximum variation from the entire density 19.7 kg / ^{m 3} is, + 1.8kg / ^{m 3,} that is, 9%.

(3) Among all the divided blocks in block Z, the maximum density is 20.5 kg / m ³ of block E, and the minimum density is 19.5 kg / m ³ of the other blocks. maximum variation of density from 19.7 kg / ^{m 3} is, + 0.8kg / ^{m 3,} i.e. 4%.

Therefore, in the block Z, the density β of the divided blocks A to I is all within the range of the overall density 19.7 (α) × (1 ± 0.06) (kg / m ³ ) of the block Z. Z is within the scope of the present invention and corresponds to an example.

[Test 1] Initial strain measurement Next, according to the Japanese EPS civil engineering method standard, each of the divided blocks is allowed to have D-20 (standard 19.0 kg / m ^{3 to} 21.5 kg / m ³ ). A weight of 50 kN / m ² which is a compressive stress was loaded, and the amount of strain (mm) was measured. The results are shown in Table 3.

As described above, the block X had a maximum density variation of +2.3 kg / m ³ (10%). As a result, although a difference in strain amount of about 2.0 mm at the maximum was obtained in each divided block, the density variation was small at +0.8 kg / m ³ (4%) at maximum in the block Z of the present invention. As a result, the difference in the amount of strain in each divided block is as small as about 1.0 mm.

  From this, the foamed resin molding block (block Z) in which the difference in the difference between the density β of each divided block and the overall density α is reduced is compared with the block (blocks X and Y) having a relatively large variation. Thus, it can be seen that the difference in strain amount is small over the entire loading surface. This proves the superiority of the foamed resin molding block according to the present invention.

[Test 2] Creep Deformation Measurement Each divided block of Test 1 was further left for 100 days with a weight loaded, and the long-term creep deformation was measured. The results are shown in Table 4.

[Discussion]
In block X, the maximum creep deformation amount in each divided block is 13.0 mm, and the minimum creep deformation amount is 6.0 mm, which is a maximum difference of 7 mm. In block Z, the maximum creep deformation amount in each divided block is The amount is 9.0 mm, and the minimum creep deformation is 7.0 mm, which is about 2 mm. Moreover, even if this difference is averaged, it can be seen that the difference between the block X and the block Z is wide.

  This also indicates that the foamed resin molded block in which the variation in the difference between the density β of each divided block and the overall density α is small is creep deformation on the entire loading surface compared to the block having a large variation. It can be seen that the difference in the amount and the difference in the average creep deformation amount are small. This proves the superiority of the foamed resin molding block according to the present invention.

  Next, some examples of a lightweight embankment structure using the foamed resin molding block 10 according to the present invention as a lightweight embankment will be described.

  The first example is a lightweight embankment structure described based on FIG. 11, in which a foamed resin molded block 10 according to the present invention is used as the EPS block 4. The light-weight embankment structure having this structure is called a single-bank embankment type light-weight embankment structure because one side surface of the light-weight embankment is a vertical surface.

  The second example is a lightweight embankment structure shown in FIG. 8, in which H-section steels 2 and 2 are vertically set in two rows at positions where both sides of the road 1 of the supporting ground 3 are regulated. In the meantime, the foamed resin molding blocks 10 according to the present invention are stacked in multiple stages as lightweight embankments. In the illustrated example, in the foamed resin molded block 10, the overall density of the foamed resin molded block 10 s near the H-shaped steels 2 and 2 is higher than that of the other foamed resin molded blocks 10. In addition, an appropriate number of concrete floor slabs 11 are arranged at appropriate positions of the light weight embankment stacked in multiple stages. On the light weight embankment, road paving composed of concrete floor slab, road floor, lower roadbed, upper roadbed, surface layer, etc. A body road 1 is formed. The light weight embankment structure having this structure is called a double straight embankment type light weight embankment structure because both sides of the light weight embankment are vertical surfaces.

  A 3rd example is the lightweight banking structure shown in FIG. 9, and is another example of a double banking type lightweight banking structure. Here, the foamed resin molded blocks 10 according to the present invention are stacked in a multi-stage as a lightweight embankment in a groove excavated in the ground, and all the used foamed resin molded blocks 10 have substantially the same overall density. Thus, it is different from the double straight type lightweight banking structure shown in FIG.

  A fourth example is a lightweight embankment structure shown in FIG. 10, and the foamed resin molded blocks 10 according to the present invention are stacked in multiple stages as a lightweight embankment above the excavation part and the ground surface of the support ground 3. The formed lightweight embankment layer has inclined surfaces on both sides of the road, and the surface portion of the lightweight embankment layer is covered with the protective soil 12. A road 1 is formed on the protective soil 12. The light-weight embankment structure having this structure is called a double-sloped light-weight embankment structure because both sides of the light-weight embankment are slopes.

  In any lightweight embankment structure, a conventionally known foamed resin molded block can be used instead of the foamed resin molded block 10 according to the present invention at a site where the loading load acts relatively small.

10: Foamed resin molding block,
10p ... divided blocks,
A1 to A4 ... foam molding machine,
20 ... 1st shaping | molding die,
21 ... molded product chamber,
27 ... Steam chamber,
30 ... second mold,
33 ... steam chamber,
28, 34 ... dispersion plate,
40, 41 ... Pressure regulating valves.

Claims (10)

Used as a lightweight embankment in civil engineering work, is a rectangular parallelepiped foamed resin molded block having a vertical length a, a horizontal length b, a height c, and a vertical length a × horizontal length b surface being the maximum surface,
When the density of the foamed resin molded block is α (kg / m ³ ), the foamed resin molded block is divided into an equal part in the longitudinal length a direction, an equal part in the lateral length b direction, and cn in the height c direction. The density β of the an × bn × cn divided blocks obtained by equally dividing (however, an, bn ≧ 3, cn ≧ 1) is all within the range of (1 ± 0.06) α (kg / m ³ ). A foamed resin molded block characterized by the above. 2. The foamed resin molded block according to claim 1, wherein α is 10 (kg / m ³ ) or more and 40 (kg / m ³ ) or less.   2. The foamed resin molded block according to claim 1, wherein the longitudinal length a is 1500 mm or more, the lateral length b is 600 mm or more, and the height c is 300 mm or more.   The foamed resin molding block according to any one of claims 1 to 3, wherein the foamed resin molding block includes a foamed resin particle preliminarily foamed with foamed resin particles and a molded product chamber and a steam chamber. A foamed resin molding block obtained by in-mold foam molding in a chamber.   A foam molding machine used to foam-mold the foamed resin molding block according to claim 4, wherein the foam molding machine has at least a molded product chamber and a steam chamber. A foam molding machine comprising a plurality of steam blowing pipes connected, and further comprising control means capable of controlling the vapor pressure and flow rate of steam supplied from the steam blowing pipes.   6. The foam molding machine according to claim 5, wherein the steam chamber includes a partition plate for partitioning a region where steam is blown from each steam blowing pipe. The density of the vertical length a, the horizontal length b, and the height c used as a lightweight embankment in civil engineering work, wherein the surface of the vertical length a × the horizontal length b is the maximum surface using the foam molding machine according to claim 5. An operation method of a foam molding machine for continuously producing a rectangular solid foam resin molding block of α (kg / m ³ ), and after producing a batch of foam resin molding blocks, an appropriate one of them The foamed resin molding block is sampled, and the sampled foamed resin molding block is divided into an equal part in the longitudinal length a direction, an equal part in the lateral length b direction, and a cn equivalent part in the height c direction (however, an, bn ≧ 3, cn ≧ 1), and each density β (kg / m ³ ) of the obtained an × bn × cn divided blocks is measured, and the density β is compared with the density α (kg / m ³ ), So that the density β of The foaming is characterized in that the control means provided for each steam blowing pipe is used to adjust the steam pressure and the steam flow rate blown into the steam chamber, and thereafter, the production operation of the foamed resin molding block of the next batch is started. How to operate the molding machine.   A lightweight embankment constructed by stacking a plurality of foamed resin molded blocks according to any one of claims 1 to 4 on a supporting ground, and a road constructed on the lightweight embankment, etc. A lightweight embankment structure comprising at least a certain ground structure.   The light weight embankment structure according to claim 8, wherein one side surface or both side surfaces of the light weight embankment are vertical surfaces.   The lightweight embankment structure according to claim 8, wherein one side surface or both side surfaces of the lightweight embankment are inclined surfaces.

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