JP2017227117A - Sleeper, sleeper laying method, and sleeper manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a sleeper capable of being easily handled by virtue of its light weight during laying work and capable of sufficiently preventing displacement on ballast by virtue of its heavy weight after being laid, and a sleeper laying method.SOLUTION: Cavity parts (12a, 12b and 12c) are provided within a rectangular parallelepiped-shaped sleeper body (11) that is formed of a composite material, and a communication part communicating with the cavity parts from any one of regions on a surface is provided. In addition, partition parts (13a and 13b) for separating a recess are provided in a region corresponding to a location for being loaded with a rail after laying of the sleeper body. Furthermore, a locking fitting (15), to which a component of a rail fastener is locked, is provided on a top surface pf the partition part.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a sleeper used for a railway track, a method for laying the sleeper, and a method for manufacturing the sleeper, and more particularly, to a technique effective for use in a synthetic sleeper that can be reduced in weight, and a method for laying and manufacturing the sleeper.

Conventionally, sleepers for railroad tracks are generally wooden sleepers used on ballast tracks and PC sleepers made of prestressed concrete. In addition, for the purpose of weight reduction, a synthetic sleeper made of a composite material made of a synthetic resin such as glass fiber and rigid urethane foam is also used in part.
In addition, as invention regarding the synthetic sleeper proposed conventionally, there exist some which are disclosed by patent document 1 and patent document 2, for example.

JP 2001-239606 A JP 2001-246665 A

The synthetic sleepers disclosed in Patent Document 1 and Patent Document 2 are both composed of a core material and a surface layer material surrounding the core material, thereby providing a light sleeper with high bending strength.
By the way, in a ballast track, there are cases where construction work is performed to replace wooden sleepers with highly durable PC sleepers. In that case, a method of replacing sleepers one by one, and a rail with rails and sleepers assembled in a ladder shape. There is a method to install in the current state.

When replacing sleepers one by one, first release the rails on the sleepers from the fasteners, remove the ballast around the sleepers, pull out the wooden sleepers, insert the PC sleepers instead, and backfill the ballast Then, the work of fixing the rail with a fastener is performed. Although such operations can be performed manually, the PC sleepers are extremely heavy, requiring considerable labor and time, and there is a problem that the work efficiency is poor.
On the other hand, in the case of the method of installing in the state of a rail, since the weight of a rail becomes very heavy, there exists a subject that it will be a large-scale construction using a special large sized heavy machine.

Therefore, by using a lightweight synthetic sleeper as disclosed in Patent Document 1 and Patent Document 2, it is possible to reduce the burden of sleeper replacement work.
By the way, in a ballast track, since the sleepers supporting the rail may be displaced in the vertical direction or the horizontal direction and the rail may be deformed, a countermeasure for preventing the displacement is desired. In order to prevent displacement of sleepers, it is known that the weight of sleepers is heavier and the resistance to the road bed is greater.

However, since synthetic sleepers are lightweight, replacement and laying work are easy, but there is a problem that the lateral resistance of the road bed is small.
Note that the synthetic sleepers according to the inventions of Patent Document 1 and Patent Document 2 use a synthetic resin for both the core material and the surface layer material in order to reduce the weight, and there is no idea of increasing the lateral resistance of the road bed.

The present invention has been made in view of the problems as described above, and is lightweight and easy to handle at the time of laying, and after laying, a sleeper capable of sufficiently preventing displacement on the roadbed and its laying. It aims at providing a method and a manufacturing method.
Another object of the present invention is to provide a sleeper capable of completing provisional laying work within a relatively short time such as at night when a commercial train does not travel, and a laying method thereof.

In order to achieve the above object, a sleeper according to the present invention is:
A hollow portion is provided inside a rectangular parallelepiped sleeper main body formed of a composite material, and a communication portion communicating with the hollow portion from any part of the surface is provided.

  According to the configuration as described above, since the hollow portion is formed in the sleeper body, it is light and easy to handle when laying, and after laying, the filler has a larger specific gravity than the material of the sleeper body in the hollow portion. The weight can be increased by injecting, thereby increasing the lateral resistance of the road bed and sufficiently preventing the rail from being displaced.

In addition, preferably, a partition portion that is continuous with the upper surface of the sleeper main body and that divides the cavity portion is provided at a portion corresponding to a position where the rail is placed after the sleeper main body is laid. .
According to such a configuration, after laying the sleeper main body and before injecting the filler into the cavity, the rail is placed and fixed with a fastener, so that the business train does not run in a relatively short time such as at night. Provisional laying work can be completed.

Furthermore, it is desirable that a locking bracket for locking a part of the rail fastener is provided on the upper surface of the partition part.
According to such a structure, the operation | work which mounts a rail and fixes with a fastener can be completed in a short time. In addition, it is possible to reduce the time required for the sleeper replacement work by adopting a procedure in which sleepers and rails are combined in advance to create a rail and laying this rail on the roadbed. Since the main body is lightweight, the rail can be lifted and laid by a general rail vehicle equipped with a crane without using special large heavy machinery.

Desirably, a plurality of cylindrical cavities are provided in the sleeper main body along the longitudinal direction of the sleeper main body, one of which has a wall and is not in communication with other cylindrical cavities. Configure as it is.
According to such a configuration, since a hollow portion that is not in communication with the other cylindrical hollow portion is provided in the sleeper body, this hollow portion can be used as a space for inserting a cable to be disposed so as to cross the track. As compared with the prior art, the cable can be arranged more easily and there is no need to provide a cover for covering the arranged cable.

In addition, a method for laying sleepers according to another invention of the present application,
Laying a sleeper body configured as described above on the roadbed;
Placing a rail on the upper surface of the partition portion of the sleeper body laid,
Fixing the rail placed on the partition with a rail fastener;
Injecting a filler having a specific gravity greater than the material of the sleeper body into the cavity of the sleeper body;
It is made to have.
According to this method, provisional laying work can be completed within a relatively short time such as at night when the business train does not travel. And after laying a sleeper, weight can be increased by inject | pouring a filler with large specific gravity into the cavity part in a sleeper, and a roadbed lateral resistance can be heightened.

Furthermore, the manufacturing method of the sleeper according to another invention of the present application,
Laying reinforcing fibers in a predetermined thickness on the cavity bottom of a formwork having a substantially rectangular cavity corresponding to the outer shape of the sleepers;
A step of installing a core at a predetermined position in the mold frame laid with reinforcing fibers;
Inserting reinforcing fibers around the core;
Pouring a resin into the mold and curing it;
It is made to have.
According to this method, it is possible to manufacture a sleeper that is reduced in weight by having a hollow portion therein and that can be easily transferred and disposed at low cost.

Preferably, the core has a space inside, a part of the wall body can be opened, and the inside of the box body having a strength that does not lose its shape is filled with a fluid substance.
After the step of pouring the resin into the mold and curing it, there is a step of taking out the fluid substance from the box.
According to such a method, an inexpensive cardboard or plastic case can be used as a box constituting the core, and an inexpensive material such as sand can be used as a fluid substance to be filled therein. Therefore, it is possible to further reduce the manufacturing cost of the sleepers having the cavities.

Furthermore, desirably, the core is a plurality of boxes that are filled with a fluid substance and arranged side by side.
After the step of pouring the resin into the mold and curing it, there is a step of breaking a part of the joint portions of the plurality of boxes.
According to this method, since the core is configured by arranging a plurality of boxes filled with a fluid substance side by side, the core can be easily installed and the resin is poured into the mold and cured. Since it has the process of fracture | rupturing a part of junction part of a some box body after the process to make, the fluid substance in all the boxes can be taken out after mold release.

  According to the sleeper and the laying method according to the present invention, it is lightweight and easy to handle when laying, can be increased in weight after laying, and displacement on the roadbed can be sufficiently prevented. Moreover, according to the sleeper and its laying method according to the present invention, there is an effect that provisional laying work can be completed within a relatively short time such as at night when the business train does not travel.

BRIEF DESCRIPTION OF THE DRAWINGS The 1st Embodiment of the sleeper based on this invention is shown, (A) is a perspective view of the sleeper before laying, (B) is a perspective view of the sleeper of the state completed by filling after laying. 1 shows a modification of the sleeper of the embodiment of FIG. 1, (A) is a perspective view showing a sleeper with a shoulder on the upper surface of the partition, and (B) is a sleeper of a first modification in which the partition is provided at both ends. (C) is a perspective view which shows the sleeper of the 2nd modification which provided the cavity inside the main body. It is a perspective view which shows the other form (railing) at the time of laying the sleeper of 1st Embodiment. An example of the sleeper of 2nd Embodiment is shown, (A) is a perspective view of the sleeper of 1st Example, (B) is a cross-sectional side view which shows the cross-sectional structure along the longitudinal direction of the sleeper of (A). is there. The other example of the sleeper of 2nd Embodiment is shown, (A) is a perspective view of the sleeper of 2nd Example, (B) is a cross-sectional side view which shows the cross-sectional structure along the longitudinal direction of the sleeper of (A) FIG. The other example of the sleeper of 2nd Embodiment is shown, (A) is a perspective view of the sleeper of 3rd Example, (B) is a cross-sectional side view which shows the cross-sectional structure along the longitudinal direction of the sleeper of (A) FIG. It is a flowchart which shows the manufacturing method of the sleeper of 2nd Embodiment in process order. It is a cross-sectional side view which shows the example of arrangement | positioning of the core provided in a sleeper main body in the manufacturing process of the sleeper of 2nd Embodiment.

Hereinafter, embodiments of sleepers according to the present invention will be described in detail with reference to the drawings.
(First embodiment)
FIG. 1 shows the structure of a sleeper according to the first embodiment. Among these, (A) is a perspective view showing the whole sleeper before laying or just after laying, and (B) is a perspective view of a sleeper in a completed state in which a filler is injected after laying.

  As shown in FIG. 1 (A), the sleeper 10 of this embodiment has three recesses 12a, 12b, and 12c formed as cavities in the upper part of a rectangular parallelepiped sleeper body 11. The sleeper body 11 is a synthetic sleeper made of a composite material made of a synthetic resin such as glass fiber and hard foamed urethane. The partition part 13a between the recesses 12a and 12b and the partition part 13b between the recesses 12b and 12c are formed corresponding to the places where the rails are placed after laying on the roadbed. As shown in FIG. 2 (A), the partitioning portions 13a and 13b may be preliminarily embedded with locking metal fittings 15 for locking rail fasteners (clips or the like) such as shoulders or studs.

  The sleeper 10 of the present embodiment is filled with a material having a specific gravity larger than that of the composite material constituting the sleeper body 11 such as concrete or mortar in the recesses 12a, 12b, and 12c, and solidifies. The completed state is as shown in (B). In FIG. 1 (B), the part to which the code | symbol 20 is attached | subjected is the solidified filler. When filling the recesses 12a, 12b, and 12c with a fluid material such as concrete, it is preferable to install a mold on each side of the sleeper body 11.

  You may comprise in the filler 20 so that the weight of the whole sleeper may become heavier than the sleeper which consists only of concrete by inserting metal lumps, such as iron. Further, the filler 20 may be one in which a metal block such as iron or lead is inserted instead of concrete. When such a metal block is used, a metal block having a shape corresponding to the shape of the recesses 12a, 12b, and 12c is separately manufactured. After the sleepers are laid, the metal blocks are formed in the recesses 12a, 12b, and 12c. It can be made to fit and can be integrated by loading an adhesive etc. into the gap between the metal block and the sleeper body 11.

  When replacing the wooden sleepers on the ballast track one by one with the sleepers 10 of this embodiment, first release the rail fasteners on the sleepers, remove the ballast around the sleepers, pull out the wooden sleepers, and replace the books After the sleeper 10 of the embodiment is inserted and the ballast is backfilled, an operation of fixing the rail with a fastener is performed.

  In the sleeper 10 of this embodiment, the recesses 12a, 12b, and 12c remain hollow immediately after laying, but even with such a cavity, the sleeper 10 has a bending strength equal to or higher than that of a wooden sleeper. The sizes of the recesses 12a, 12b, and 12c are set in advance. Originally, synthetic sleepers have sufficient bending strength compared to wooden sleepers, and even if concave portions are formed, it is possible to form a synthetic sleeper having a bending strength higher than that of wooden sleepers. .

  Therefore, there is no problem even if the train runs on the sleepers that are laid with a cavity as described above. Then, after the sleeper laying work is completed, a filler such as concrete can be poured into the recesses 12a, 12b, and 12c in order over time and solidified, thereby increasing the weight of the sleeper. It is possible to increase the lateral resistance of the road bed.

In addition, when it is not necessary to run the train immediately after laying the sleepers, the partition portions 13a and 13b are not provided at positions corresponding to the rails, for example, as shown in FIG. It is also possible to form a continuous recess 12.
Further, as shown in FIG. 2C, a cavity 14 extending in the longitudinal direction is formed inside the sleeper main body 11, and a communicating portion 14a communicating with the cavity 14 is provided on a part of the upper surface or the like. It is also possible.

Moreover, as shown in FIG. 3, the sleeper 10 of this embodiment can be installed on a roadbed in the state of the rail which assembled the rail and the sleeper in the shape of a ladder.
And the sleeper 10 of this embodiment has a recessed part before laying as mentioned above, and since the weight is about half compared with the conventional synthetic sleeper, the weight of the assembled state is greatly increased. Can be reduced. As a result, it is possible to perform laying work with a general rail vehicle having a crane without using a special large heavy machine. In addition, in FIG. 3, illustration of a rail fastener is abbreviate | omitted.

  Although the invention made by the present inventor has been specifically described based on the embodiment, the present invention is not limited to the embodiment. For example, in the above-described embodiment, the state shown in FIG. 1B is described as a completed state. However, the surface protective layer made of resin or the like on the sleeper body 11 and the filler 20 such as concrete or mortar in the recess. It is good also as a completed state by forming. Moreover, in the said embodiment, although what provided the recessed part in which a filler is inject | poured was provided in the upper surface of the sleeper main body 11, the position of a recessed part is not limited to an upper surface, A side surface, a front surface, a rear surface, etc. may be sufficient. .

(Second Embodiment)
Next, a second embodiment of a sleeper according to the present invention and a manufacturing method thereof will be described.
In the first example of the sleeper 10 of the second embodiment, as shown in FIG. 4 (A), in the sleeper body 11 made of a composite material, the partition portions 13a and 13b provided with shoulders 15 on the upper surface are sandwiched, Three rectangular parallelepiped cavities 16a, 16b, and 16c are formed, and communication ports 17a, 17b, and 17c for communicating the cavities 16a, 16b, and 16c with the external space are provided in the upper part of the main body.

  FIG. 4B shows a structure in which the sleeper 10 shown in FIG. 4A is cross-sectioned along the longitudinal direction. In FIG. 4B, reference numeral 18 denotes an implantation bolt for fixing the shoulder 15, which is embedded in the composite material constituting the partition portions 13 a and 13 b of the sleeper body 11. Reference numeral 19 denotes a clip that is inserted through the shoulder 15 and fastens the flange of the rail 30.

The 2nd Example of the sleeper 10 of 2nd Embodiment is shown by FIG.
As shown in FIG. 5 (A), the sleeper 10 of the second embodiment has a communication cavity 16d that communicates with the lower part of the three cavities 16a, 16b, and 16c in the sleeper main body 11 so that these cavities communicate with each other. Except this point, it is the same as the sleeper of the first embodiment shown in FIG.
In the sleepers of the first embodiment of FIG. 4 and the second embodiment of FIG. 5, cavities 16a to 16d are formed using a core, as will be described in detail later. Moreover, the sleepers 10 are transported in a hollow state after manufacturing, and after the sleepers are installed on the roadbed, concrete or mortar is filled into the hollow portions 16a to 16d from the communication ports 17a, 17b, and 17c. Solidified. As a result, the weight of sleepers can be increased, and the lateral resistance of the road bed can be increased.

FIG. 6 shows a third example of the sleeper 10 of the second embodiment.
As shown in FIG. 6 (A), the sleeper 10 of the third embodiment is provided with four cavities 16A, 16B, 16C, and 16D in two stages in which three cylinders are arranged horizontally in the sleeper main body 11. Therefore, the upper cavity portions 16A, 16B, and 16C are divided so as to sandwich the partition portions 13a and 13b, and the lower cavity portion 16D is formed continuously in the longitudinal direction. These cylindrical cavities 16A to 16D are formed using a core (the shape is not a rectangular parallelepiped but a cylinder) as in the first embodiment of FIG. 4 and the second embodiment of FIG. Are configured to communicate with each other.

Further, one of the three cylindrical portions of the lower hollow portion 16D may be formed so as not to communicate with other hollow portions (including 16A, 16B, and 16C). By providing such a non-communication hollow portion, the hollow portion can be used as a space for inserting a cable disposed so as to cross the track.
In a track using conventional sleepers, when a cable is arranged so as to cross the track, an operation such as creating a gap between the sleeper and the ballast, and a work of covering the cable with a cover after the arrangement are necessary. However, when a sleeper having a hollow portion for inserting a cable as in this embodiment is used, when a cable that traverses the track is to be arranged, the arrangement work can be easily performed. In addition, there is an advantage that it is not necessary to provide a cover for covering the arranged cable.

Next, an example of a method for manufacturing a lightweight sleeper as in the above-described two embodiments will be described with reference to the flowchart of FIG.
First, a forming mold having a recess corresponding to the outer shape of the sleeper main body 11 to be manufactured and a core having an outer shape (a rectangular parallelepiped, a cylindrical shape, etc.) corresponding to the shape of the cavity to be formed inside the sleeper are prepared. Then, reinforcing fibers such as glass fibers are spread on the bottom of the mold so as to have a thickness corresponding to the thickness of the bottom wall portions of the cavities 16a to 16d (step S1). Subsequently, the core is disposed on the laid reinforcing fiber layer, and the reinforcing fiber is inserted into a gap between the core and the surrounding mold (step S2).

  For the core, for example, a container formed of a material having a strength that does not cause deformation in the sheet state, such as cardboard, cardboard, or polypropylene, is used. Then, each container is filled with a fluid substance such as sand. In the case where corrugated cardboard is used among the container forming materials, the core can be formed at a very low cost. The fluid substance is not limited to sand, and may be a granular material such as glass beads or a liquid material.

  Further, for example, in the sleeper as in the second embodiment of FIG. 5, it is possible to configure the entire continuous core as one container, but as shown in FIG. 8, there are five containers C1. ˜C5 may be arranged. In the case of FIG. 8, three types of five containers having different sizes are required for one sleeper. The number of containers constituting the core is not limited to five, and may be divided into a larger number of containers. Further, for example, smaller cores having the same shape may be arranged to form a core having a predetermined size.

  Subsequent to step S2, the cylindrical core is disposed vertically at a position corresponding to the communication ports 17a, 17b, 17c (step S3). In addition, in the sleeper which provides an embedded bolt, an embedded bolt is arrange | positioned in the site | part used as the partition part of a sleeper main body by step S3. Next, reinforcing fibers are spread over the hollow core forming cores (containers C1 to C5) and around the cylindrical core for forming the communication port (step S4), and synthetic resin such as urethane is placed in the mold And cured (step S5). The cylindrical core may be filled with a fluid substance like the containers C1 to C5, or may be arranged in an empty state by making the thickness thicker than the containers C1 to C5.

  After step S5, the solidified sleeper body is removed from the mold (step S6), the sleeper body is turned sideways or upside down to remove the fluid substance from the cylindrical core, and a cutter or the like is placed inside the cylindrical core. A tool is inserted, a part of the joint surface of the containers C1 to C5 used as the core is broken, and the flowable substance is allowed to flow out from all the containers (step S7), thereby completing a completed state.

In addition, the said procedure is an example and various deformation | transformation are possible. For example, the step S3 in which the cylindrical core is disposed vertically in the position corresponding to the communication ports 17a, 17b, and 17c is eliminated, and instead the position corresponding to the communication ports 17a, 17b, and 17c is provided after step S6. A step of making a hole with a drill or the like may be provided.
Moreover, in the above procedure, the case where the sleepers are manufactured in a normal posture (the state where the upper surface when the roadbed is installed is the upper side when manufactured) has been described, but the sleepers are manufactured so that the sleepers are completed in an inverted posture. It is also possible to do.

  Further, the sleeper of the third embodiment shown in FIG. 6 using a cylindrical core is made of a resin having such a strength that one of the lower three is not deformed when the resin is injected into the mold. The core made of resin and having a non-deformable resin core in the cylindrical container that becomes the core in step S7 is prevented from breaking the joint with the adjacent core. Can be used as a space through which the cable is inserted. In addition, the core that forms this cable insertion hole should have a length so that both ends thereof face both end faces of the sleeper, but the sleeper body is a little shorter than the length of the sleeper. After the resin is cured, a hole may be made in the end face and opened.

  The sleepers shown in FIGS. 4 to 6 are manufactured by laminating a prepreg (a semi-cured sheet in which a reinforcing fiber is impregnated with a resin) so as to have a predetermined shape, and then curing by heat treatment. However, currently available prepregs are relatively expensive. Therefore, as in the above embodiment, a lightweight sleeper according to the present invention can be manufactured at a very low cost by manufacturing a sleeper using a core formed of an inexpensive material such as cardboard and sand. There is an advantage that you can.

10 sleepers 11 sleeper bodies 12a, 12b, 12c recesses (cavities)
13a, 13b Partition 15 Shoulder (locking bracket)
16a-16d, 16A-16D Cavity part 17a-17c Communication port 20 Filler 30 Rail

Claims (8)

  A sleeper characterized in that a hollow portion is provided inside a rectangular parallelepiped sleeper body made of a composite material, and a communication portion that communicates with the hollow portion from any part of the surface is provided.   The partition part which the upper surface continues to the upper surface of the said sleeper main body, and divides | segments the said cavity part is provided in the site | part corresponding to the location where a rail is mounted after laying of the said sleeper main body. Sleepers described in.   The sleeper according to claim 2, wherein a locking bracket for locking a part of the rail fastener is provided on an upper surface of the partition part.   A plurality of cylindrical cavities are provided in the sleeper main body along the longitudinal direction of the sleeper main body, one of which has a wall and is not in communication with other cylindrical cavities. The sleeper according to any one of claims 1 to 3, characterized in that Laying the sleeper body according to any one of claims 2 to 4 on the roadbed;
Placing a rail on the upper surface of the partition portion of the sleeper body laid,
Fixing the rail placed on the partition with a rail fastener;
Injecting a filler having a specific gravity greater than the material of the sleeper body into the cavity of the sleeper body;
A method for laying sleepers, characterized by comprising: Laying reinforcing fibers in a predetermined thickness on the cavity bottom of a formwork having a substantially rectangular cavity corresponding to the outer shape of the sleepers;
A step of installing a core at a predetermined position in the mold frame laid with reinforcing fibers;
Inserting reinforcing fibers around the core;
Pouring a resin into the mold and curing it;
A method for manufacturing sleepers, comprising: The core has a space inside, a part of the wall body can be opened, and the inside of the box body having a strength that does not lose its shape is filled with a fluid substance,
The sleeper manufacturing method according to claim 6, further comprising a step of removing the fluid substance from the box after the step of pouring the resin into the mold and curing the resin. The core is arranged by arranging a plurality of boxes filled with a fluid substance,
The method for manufacturing a sleeper according to claim 7, further comprising a step of breaking a part of a joint portion of the plurality of box bodies after the step of pouring and curing the resin into the mold.

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