U.S. patent application number 11/814881 was filed with the patent office on 2008-06-12 for grating using press process and method thereof.
Invention is credited to Jin-Hwan Kim.
Application Number | 20080135466 11/814881 |
Document ID | / |
Family ID | 36740765 |
Filed Date | 2008-06-12 |
United States Patent
Application |
20080135466 |
Kind Code |
A1 |
Kim; Jin-Hwan |
June 12, 2008 |
Grating Using Press Process and Method Thereof
Abstract
A grating (1) and a method of manufacturing the same using a
pressing process are disclosed. The grating manufacturing method of
the present invention includes the step of bending opposite ends of
a metal plate to form a main surface (5) and supports (4), each
having a predetermined height, the step of drawing a plurality of
water drain slot formation portions of the main surface (5) to form
slot frame parts (3), each having a predetermined depth, and the
step of perforating bottoms of the slot frame parts (3) to form
water drain slots (2). Therefore, the present invention provides a
grating (1) that can sustain a relatively heavy load despite being
manufactured through a simple pressing process, and a method of
manufacturing the same through the pressing process.
Inventors: |
Kim; Jin-Hwan; (Gyeonggi-Do,
KR) |
Correspondence
Address: |
IPLA P.A.
3580 WILSHIRE BLVD., 17TH FLOOR
LOS ANGELES
CA
90010
US
|
Family ID: |
36740765 |
Appl. No.: |
11/814881 |
Filed: |
January 26, 2006 |
PCT Filed: |
January 26, 2006 |
PCT NO: |
PCT/KR06/00301 |
371 Date: |
July 26, 2007 |
Current U.S.
Class: |
210/164 ;
72/324 |
Current CPC
Class: |
B21D 47/005
20130101 |
Class at
Publication: |
210/164 ;
72/324 |
International
Class: |
B21D 35/00 20060101
B21D035/00; B21D 43/28 20060101 B21D043/28; E04F 19/10 20060101
E04F019/10; E04C 2/42 20060101 E04C002/42; E03F 5/06 20060101
E03F005/06; E01C 9/10 20060101 E01C009/10 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 27, 2005 |
KR |
10-2005-0007404 |
Claims
1. A method of manufacturing a grating using a pressing process,
comprising the steps of: bending opposite ends of a metal plate to
form a main surface and supports, each having a predetermined
height; drawing a plurality of water drain slot formation portions
of the main surface to form slot frame parts, each having a
predetermined depth; and perforating bottoms of the slot frame
parts to form water drain slots.
2. The method of manufacturing the grating using the pressing
process according to claim 1, wherein each of the heights of the
supports and the depths of the slot frame parts is equal to a depth
of a support seat of each of sewer walls of a sewer.
3. The method of manufacturing the grating using the pressing
process according to claim 1, wherein a length of each of the slot
frame parts is greater than a width of the sewer and is less than a
width of the support seats of the sewer walls.
4. The method of manufacturing the grating using the pressing
process according to claim 1, wherein a plurality of through holes
is formed through a part defined between the adjacent water drain
slots.
5. The method of manufacturing the grating using the pressing
process according to claim 1, wherein each of the supports is bent
at an angle corresponding to a slope angle of the support seat of
each of the sewer walls.
6. The method of manufacturing the grating using the pressing
process according to claim 1, further comprising the step of:
mounting a subsidiary frame both to a lower end of each of the
supports and to parts of lower surfaces of opposite ends of the
slot frame parts.
7. The method of manufacturing the grating using the pressing
process according to claim 1, further comprising the step of:
bending each of the supports such that a height thereof is greater
than a depth of each of the slot frame parts, and bending the
support several times at 90.degree., thus forming a multiply bent
part, wherein the opposite ends of the slot frame parts are in
close contact with the related multiply bent part, so that the slot
frame parts are supported by the multiply bent parts.
8. A method of manufacturing a grating using a pressing process,
comprising the steps of: bending opposite ends of a metal plate to
form a main surface and supports, each having a predetermined
height; drawing a plurality of water drain slot formation portions
of the main surface to form slot frame parts, each having a
predetermined depth; perforating bottoms of the slot frame parts to
form water drain slots; uniting front surface members to opposite
ends of the supports; and charging a filling material into a space
defined by the main surface, the supports and the front surface
members.
9. The method of manufacturing the grating using the pressing
process according to claim 8, further comprising the step of:
mounting a subsidiary frame to each of opposite ends of a lower
surface of the main surface turned upside down.
10. A method of manufacturing a grating using a pressing process,
comprising the steps of: drawing a plurality of water drain slot
formation portions of a main surface of a metal plate to form slot
frame parts, each having a predetermined length; and perforating
bottoms of the slot frame parts to form water drain slots.
11. A method of manufacturing a grating using a pressing process,
comprising the steps of: bending opposite ends of a metal plate to
form a main surface and supports, each having a predetermined
height; drawing a plurality of first water drain slot formation
portions of the main surface to form first slot frame parts, each
having a predetermined depth; drawing parts between lower ends of
the first slot frame parts to form a plurality of second slot frame
parts; perforating bottoms of the second slot frame parts to form a
plurality of water drain slots; uniting front surface members to
opposite ends of the supports; and charging a filling material into
a space defined by the main surface, the supports and the front
surface members.
12. A grating manufactured through the method according to claim 1.
Description
TECHNICAL FIELD
[0001] The present invention relates, in general, to gratings and
methods of manufacturing the same and, more particularly, to a
grating in which a plurality of water drain slots is formed by
deep-drawing a metal plate using a press machine without a welding
process, and slot frame parts formed by deep-drawing serve to
sustain load applied to the grating, thus having a structure
capable of sustaining a relatively heavy load despite the simple
manufacturing method thereof, and to a method of manufacturing the
same through the pressing process.
BACKGROUND ART
[0002] Generally, sewers are formed at sides of roadways or
streets, so that rainwater and the like flows into a sewer system
through the sewers. A grating is disposed at upper ends of each
sewer opening, such that a person or a vehicle can pass over the
sewer but rainwater can flow into it.
[0003] There are various methods of manufacturing such a grating. A
method using a molding process is a representative example.
However, in the case of a method using a molding process, an
excessively large amount of steel material is required for a
molding process, so that there are disadvantages in that the
manufactured grating is too heavy, and the manufacturing cost
thereof is increased. Therefore, recently, the method using the
molding process is seldom used. Meanwhile, recently, gratings
having lattice structures have been widely used.
[0004] FIG. 1 is a perspective view showing the construction of a
representative grating having a lattice structure.
[0005] As shown in FIG. 1, in the conventional grating having the
lattice structure, a plurality of I-bars 20, each of which has
therein notches (not shown) at regular intervals, is longitudinally
fastened to a rectangular main body 10 by welding. Bearing bars 30
are seated into the notches of the I-bars 20 in directions crossing
over the I-bars 20. Each bearing bar 30 is fixed to the main body
10 and the I-bars 20 by welding.
[0006] However, in the case of the conventional grating having the
above-mentioned lattice structure, the main body 10, the I-bars 20
and the bearing bars 30 must be manufactured through separate
processes before being assembled together. Therefore, there is a
problem of a complex manufacturing process.
[0007] Furthermore, the I-bars 20 and the bearing bars 30 are fixed
to the main body 10 of the grating by welding, and the I-bars 20
and the bearing bars 30 are also fixed by welding at junctions
between them. Therefore, labor costs increase due to the increased
number of welders, and the time required for manufacturing the
grating is increased, so that there is a problem in that the unit
cost of production is increased.
[0008] To solve the above-mentioned problems, a method of
manufacturing a grating through a pressing process has been
proposed. However, because the bearing power of the conventional
grating manufactured by this method is insufficient, it cannot be
used in a sewer, over which vehicles pass, or to which a heavy load
is applied. That is, this grating has been restrictively used in
places over which vehicles seldom pass.
[0009] Therefore, a grating, that makes it possible to overcome the
problems of the conventional grating manufacturing method, that is
manufactured through a simple process, and that can sustain a heavy
load, is required.
DISCLOSURE OF INVENTION
Technical Problem
[0010] Accordingly, the present invention has been made keeping in
mind the above problems occurring in the prior art, and an object
of the present invention is to provide a grating, which can sustain
a relatively heavy load, and a grating manufacturing method, which
has a reduced number of steps thanks to the use of a press
machine.
Technical Solution
[0011] In an aspect, the present invention provides a method of
manufacturing a grating using a pressing process, comprising the
steps of: bending opposite ends of a metal plate to form a main
surface and supports, each having a predetermined height;
[0012] drawing a plurality of water drain slot formation portions
of the main surface to form slot frame parts, each having a
predetermined depth; and perforating bottoms of the slot frame
parts to form water drain slots.
[0013] In another aspect, the present invention provides a method
of manufacturing a grating using a pressing process, comprising the
steps of: bending the opposite ends of a metal plate to form a main
surface and supports, each of which has a height equal to the depth
of a support seat of each sewer wall; cutting the metal plate along
a longitudinal central line of each of a plurality of water drain
slot formation portions to the length of each water drain slot to
be formed; cutting the metal plate at each of opposite ends of the
cut longitudinal central line of each water drain slot formation
portion in lateral opposite directions of the cut longitudinal
central line to lengths corresponding to the height of the support;
and bending the cut water drain slot formation portions of the
metal plate downwards and forming the slot frame parts.
[0014] In a further aspect, the present invention provides a method
of manufacturing a grating using a pressing process, comprising the
steps of: bending opposite ends of a metal plate to form a main
surface and supports, each having a predetermined height; drawing a
plurality of water drain slot formation portions of the main
surface to form slot frame parts, each having a predetermined
depth; perforating bottoms of the slot frame parts to form water
drain slots; uniting front surface members to opposite ends of the
supports; and charging a filling material into a space defined by
the main surface, the supports and the front surface members.
[0015] In yet another aspect, the present invention provides a
method of manufacturing a grating using a pressing process,
comprising the steps of: drawing a plurality of water drain slot
formation portions of a main surface of a metal plate to form slot
frame parts, each having a predetermined length; and perforating
bottoms of the slot frame parts to form water drain slots.
[0016] In still another aspect, the present invention provides a
method of manufacturing a grating using a pressing process,
comprising the steps of: bending opposite ends of a metal plate to
form a main surface and supports, each having a predetermined
height; drawing a plurality of first water drain slot formation
portions of the main surface to form first slot frame parts, each
having a predetermined depth; drawing parts between lower ends of
the first slot frame parts to form a plurality of second slot frame
parts; perforating bottoms of the second slot frame parts to form a
plurality of water drain slots; uniting front surface members to
opposite ends of the supports; and charging a filling material into
a space defined by the main surface, the supports and the front
surface members.
[0017] Other objects, features and advantages of the present
invention will be more clearly understood from the following
detailed description taken in conjunction with the accompanying
drawings.
Advantageous Effects
[0018] The present invention provides a grating, which can sustain
a relatively heavy load despite being manufactured through a simple
pressing process, and a method of manufacturing the same through
the pressing process.
[0019] Although the preferred embodiments of the present invention
have been disclosed for illustrative purposes, those skilled in the
art will appreciate that various modifications, additions and
substitutions are possible, without departing from the scope and
spirit of the invention as disclosed in the accompanying
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a perspective view showing the construction of a
conventional grating;
[0021] FIG. 2 is a perspective view showing the construction of a
grating manufactured through a pressing process, according to a
first embodiment of the present invention;
[0022] FIG. 3 is a bottom perspective view of the grating of FIG.
2;
[0023] FIG. 4 is a perspective view showing the construction of a
grating manufactured through a pressing process, according to a
modification of the first embodiment of the present invention;
[0024] FIG. 5 is a front sectional view showing the grating placed
on a support seat of a sewer wall according to the first embodiment
of the present invention;
[0025] FIG. 6 is a front sectional view showing a grating according
to the first embodiment placed on slope support seats of sewer
walls;
[0026] FIG. 7 is a perspective view showing the construction of a
grating manufactured through a pressing process, according to a
second embodiment of the present invention;
[0027] FIGS. 8 and 9 are perspective views showing the construction
of a grating manufactured through a pressing process, according to
a third embodiment of the present invention;
[0028] FIG. 10 is a front sectional view showing the grating
according to the third embodiment placed on support seats of sewer
walls;
[0029] FIG. 11 is a front sectional view showing a modification of
the fourth embodiment of the present invention;
[0030] FIG. 12 is a perspective view showing the construction of a
grating manufactured through a pressing process, according to a
fourth embodiment of the present invention;
[0031] FIG. 13 is a front sectional view showing the grating placed
on the sewer walls according to the fourth embodiment of the
present invention;
[0032] FIG. 14 is a front sectional view showing installation of a
grating manufactured through a pressing process, according to a
fifth embodiment of the present invention;
[0033] FIG. 15 is a front sectional view showing installation of a
grating manufactured through a pressing process, according to a
sixth embodiment of the present invention; and
[0034] FIG. 16 is a front sectional view showing installation of a
grating manufactured through a pressing process, according to a
sixth embodiment of the present invention.
BEST MODE FOR CARRYING OUT THE INVENTION
[0035] Hereinafter, preferred embodiments of the present invention
will be described in detail with reference to the attached
drawings.
[0036] FIG. 2 is a perspective view showing the construction of a
grating 1 manufactured through a pressing process, according to a
first embodiment of the present invention. FIG. 3 is a bottom
perspective view of the grating 1 of FIG. 2.
[0037] As shown in FIGS. 2 and 3, the grating 1 according to the
first embodiment includes two supports 4, which are formed by
bending opposite ends of a metal plate. A plurality of water drain
slots 2 is formed through a main surface 5.
[0038] The water drain slots 2 are defined in respective slot frame
parts 4, which are formed by pressing parts of the metal plate
downwards, that is, by deep-drawing the main surface 5 using a
machining means such as a press machine.
[0039] Each slot frame part 4 is deep-drawn at an appropriate
pressure such that it has the same height as the supports 4, and,
thereafter, is perforated.
[0040] FIG. 4 is a perspective view showing the construction of a
grating manufactured through a pressing process, according to a
modification of the first embodiment.
[0041] In the case of a relatively wide water drain slot 2, a wheel
of a cart or a heel of a shoe may be trapped in the water drain
slot 2. To prevent this problem from occurring, the modification of
the first embodiment of FIG. 4 has a structure in which the width
of each water drain slot 2 is relatively narrow and a plurality of
through holes 8 is formed in a part between adjacent water drain
slots 2 to ensure smooth drainage.
[0042] FIG. 5 is a front sectional view showing the grating 1 of
the first embodiment placed on support seats 40 of sewer walls
30.
[0043] As shown in FIG. 5, the height of the supports 4 is equal to
the height (h) of the support seats 40 of the sewer wall, such that
the grating 1 of the present invention does not interfere with a
person or object passing over it after having been placed on the
support seats 40 of the sewer wall.
[0044] The length of each slot frame part 3 is greater than the
width (t) of a sewer 20 but is less than the distance (T) between
the support seats 40 of sewer walls. Therefore, opposite ends of
the slot frame parts 3 are placed on bottoms 41 of the support
seats 40 of sewer walls, so that the slot frame parts 3 can serve
as support bodies along with the supports 4. Thus, even if a large
load is applied to the main surface 5, the grating can sustain the
load.
[0045] FIG. 6 is a front sectional view showing a grating 1
according to the first embodiment placed on slope support seats 40
of sewer walls 30.
[0046] In the case of the grating 1 of FIG. 5 having the support
seat 40 with a perpendicular structure, noise may be generated by
lateral movement of the grating 1. Therefore, preferably, the
support seats 40 of the sewer walls 30 are slanted, and the support
4 is bent at an angle, at which the support seat 40 of the sewer
wall 30 is slanted.
MODE FOR THE INVENTION
[0047] FIG. 7 is a perspective view showing the construction of a
grating 1 manufactured through a pressing process, according to a
second embodiment of the present invention.
[0048] In the grating 1 according to the second embodiment, the
method of forming supports 4 by bending the opposite ends of a
metal plate is the same as that of the first embodiment, but the
method of forming both a water drain slot 2 and a slot frame part 3
differs from that of the first embodiment.
[0049] In the second embodiment, after parts of a main surface 5
for formation of the water drain slots 2 are cut, they are bent
downwards, so that the cut parts of the metal plate forms the slot
frame parts 3.
[0050] Furthermore, in the case of the second embodiment, the
opposite ends of the slot frame parts 3 are placed on bottoms 41 of
support seats 40 of sewer walls, so that the slot frame parts 3 can
serve as support bodies along with the supports 4. Thus, even if a
large load is applied to the main surface 5, the grating can
sustain the load.
[0051] Meanwhile, a method of manufacturing the grating 1 according
to the second embodiment includes the step of bending the opposite
ends of a metal plate to form the main surface 5 and the supports
4, each of which has a height equal to the depth (h) of the support
seat 40 of each sewer wall 30. The method further includes the step
of cutting the metal plate along a longitudinal central line of
each of a plurality of water drain slot formation portions to the
length of each water drain slot 2 to be formed. The method further
includes the step of cutting the metal plate at each of opposite
ends of the cut longitudinal central line of each water drain slot
formation portion in lateral opposite directions of the cut
longitudinal central line to lengths corresponding to the height of
the support 4. The method further includes the step of bending the
cut water drain slot formation portions of the metal plate
downwards and forming the slot frame parts 3.
[0052] FIGS. 8 and 9 are perspective views showing the construction
of a grating 1 manufactured through a pressing process, according
to a third embodiment of the present invention.
[0053] In the third embodiment, as shown in FIG. 8, a front surface
member 6 is provided on each of open front and rear sides of the
grating and fastened at opposite ends thereof to respective
supports 4 by welding or the like. Thereafter, the grating 1 is
turned upside down such that it has a box shape, which is open at
an upper surface thereof. Subsequently, as shown in FIG. 9, the
grating 1 is filled with filling material.
[0054] Stone, synthetic resin, such as polyurethane, or rubber is
used as filling material. In this embodiment, colored pebbles are
charged into spaces in the grating other than water drain slots,
thus providing a grating 1 that is solid and has a good
appearance.
[0055] FIG. 10 is a front sectional view showing the grating 1
according to the third embodiment placed on support seats 40 of
sewer walls.
[0056] As shown in FIG. 10, in the third embodiment, opposite ends
of slot frame parts 3 are placed on respective bottoms of the
support seats of the sewer walls, so that the slot frame parts 3
serve as support bodies along with the supports 4. Thus, even if a
relatively heavy load is applied to the grating, the grating can
sustain the load. Particularly, in the third embodiment, the
filling material 7, which is charged into the space defined between
the supports 4 and the slot frame parts 3, serves as another
support body, thus providing a stronger structure.
[0057] A method of manufacturing the grating 1 according to the
third embodiment includes the step of bending the opposite ends of
a metal plate to form a main surface 5 and the supports 4, each of
which has a height equal to the depth (h) of the support seat 40 of
each sewer wall 30. The method further includes the step of
deep-drawing a plurality of water drain slot formation portions on
the main surface 5 such that the water drain slot formation
portions of the metal plate are depressed by the height of the
supports 4, thus forming the slot frame parts 3. The method further
includes the step of perforating bottoms of the slot frame parts 3
to form water drain slots 2, and the step of uniting the opposite
ends of the supports 4 to the related front surface member 6. The
method further includes the step of charging the filling material 7
into a space defined by the main surface 5, the supports 4 and the
front surface members 6.
[0058] FIG. 11 is a front sectional view showing a modification of
the third embodiment of the present invention.
[0059] As shown in FIG. 11, in this modification, first slot frame
parts 3 are formed by deep-drawing the surface of the grating by a
predetermined depth less than the height (h) of the supports 4.
Thereafter, second slot frame parts 9 are formed by deep-drawing
the surface from the lower ends of the first slot frame parts 3 by
the height of the supports 4 using a smaller press machine.
Subsequently, a plurality of water drain slots 2 is perforated. The
grating 1 is thereafter turned upside down, and filling material 7
is charged into a space defined in the grating 1.
[0060] In detail, the method of manufacturing the grating 1
according to the modification of the third embodiment includes the
step of bending the opposite ends of a metal plate to form a main
surface 5 and the supports 4, each of which has a height equal to
the depth (h) of the support seat 40 of each sewer wall 30. The
method further includes the step of deep-drawing a plurality of
first water drain slot formation portions on the main surface 5
such that the first water drain slot formation portions of the
metal plate are depressed by a predetermined depth, thus forming
the first slot frame parts 3. The method further includes the step
of deep-drawing parts between the lower ends of the first slot
frame parts 3 to form a plurality of second slot frame parts 9. The
method further includes the step of perforating bottoms of the
second slot frame parts 9 to form water drain slots 2, and the step
of uniting the opposite ends of the supports 4 to the related front
surface member 6. The method further includes the step of charging
the filling material 7 into a space defined by the main surface 5,
the supports 4 and the front surface members 6.
[0061] FIG. 12 is a perspective view showing the construction of a
grating 1 manufactured through a pressing process, according to a
fourth embodiment of the present invention.
[0062] The grating 1 according to the fourth embodiment has a
structure suitable for a "U"-shaped sewer 20 having no support seat
40 on a sewer wall 30. In a process of manufacturing the grating of
this embodiment, because the support seat 40 does not exist in the
sewer wall 30, the step of forming the supports 4 is eliminated,
unlike the first embodiment.
[0063] In detail, the method of manufacturing the grating 1
according to the fourth embodiment includes the step of
deep-drawing a plurality of water drain slot formation portions on
the upper surface of a metal plate such that the water drain slot
formation portions of the metal plate are depressed by a
predetermined depth, thus forming slot frame parts 3. The method
further includes the step of perforating the bottoms of the slot
frame parts 3 to form water drain slots 2.
[0064] FIG. 13 is a front sectional view showing the grating placed
on the sewer walls 30 according to the fourth embodiment of the
present invention.
[0065] As shown in FIG. 13, the slot frame parts 3 are disposed in
the sewer 30, while the opposite ends of the main surface 5 are
placed on the respective sewer walls 30.
[0066] In the case of the fourth embodiment, the slot frame parts 3
have appropriate thicknesses and disperse load applied to the main
surface 5, so that the grating can sustain a relatively heavy
load.
[0067] FIGS. 14 through 16 illustrate modifications of the first
through fourth embodiments adapted to the case in which the height
of the support seat 40 differs from that of the grating.
[0068] FIG. 14 is a front sectional view showing the installation
of a grating 1 manufactured through a pressing process, according
to a fifth embodiment of the present invention. The grating 1 of
this embodiment includes a subsidiary height adjustment frame 50,
which is welded both to the slot frame part 3 and each support 4 to
adapt to the height of support seats 40 of the sewer walls 30,
which is different from that of the grating. In other words, this
embodiment can adapt to the height of various support seats 40.
[0069] FIG. 15 is a front sectional view showing the installation
of a grating 1 manufactured through a pressing process, according
to a sixth embodiment of the present invention. In the case of FIG.
15, subsidiary height adjustment frames 50 are attached to the
surface of a grating 1 which is turned upside down. In other words,
the subsidiary height adjustment frames 50 are welded to a main
surface 5. Furthermore, filling material 7 is charged into the
grating 1 which is adjusted in height.
[0070] FIG. 16 is a front sectional view showing installation of a
grating 1 manufactured through a pressing process, according to a
seventh embodiment of the present invention. Referring to FIG. 16,
each support 4 is bent such that the height thereof is greater than
the depth of a slot frame part 3 and, thereafter, the support 4 is
bent several times at 90.degree., thus forming a multiply bent part
4a. Each of the opposite ends of the slot frame parts 3 is in close
contact with the related multiply bent part 4a, so that the slot
frame parts 3 are supported on the multiply bent parts 4a. As such,
the grating 1 of this embodiment has a structure such that the
height thereof can be adjusted without a welding process for a
separate subsidiary frame 50.
[0071] Although the gratings for sewers have been explained in the
preferred embodiment of the present invention, the present
invention is not limited to this. The present invention can be
applied to various kinds of gratings, such as a tree support
grating, which is placed on the upper end of a tree protective
unit, which is installed around a tree to protect it. Of course,
these modifications fall within the bounds of the present
invention.
* * * * *