KR20150072757A

KR20150072757A - Drain board and method for forming the same

Info

Publication number: KR20150072757A
Application number: KR1020130160266A
Authority: KR
Inventors: 변종석
Original assignee: 변종석
Priority date: 2013-12-20
Filing date: 2013-12-20
Publication date: 2015-06-30

Abstract

Disclosed is a drain plate and a method of forming a drain plate that reduce production cost and productivity, as compared with the conventional drain plate. The disclosed drainage plate is composed of a flat plate which is integrally formed of a thermoplastic resin and has a flat plate and a plurality of cups spaced apart from each other on the plate and protruding downward to the same depth, (cup). A plurality of female couplers (female couplers) disposed on the outer circumferential portion of the plate and projecting downward, and a plurality of downwardly female couplers (female couplers) for fitting the male couplers. and a coupler. The male coupler and the female coupler all have an engraved upper side and an embossed lower side.

Description

[0001] Drain board and method for forming the same [0002]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a drain plate used for forming drainage passages in a floor at a construction site and a method for forming a drain plate.

The drain plate is used to form drainage passages on the floor at the construction site. 1 is a cross-sectional view schematically showing a construction of a drainage board. Referring to FIG. 1, a drainage board 5 has a structure in which a plurality of cups 7 opened upward on a flat board are spaced apart. The floor slab layer 1 is first formed in the floor construction and the drain plate 5 is laid on the floor slab layer 1. The concrete is laid on the drain plate 5 and cured to form the floor concrete layer 3. [ This forms a drainage passage (9) between the adjacent cups (7) below the rigid concrete floor. In the absence of the drainage passage 9, when water is collected from the floor and water is introduced into the floor, the water may penetrate into the bottom slab layer 1 to weaken the structure and cause a leakage problem. However, 9), so that the water on the floor is guided to the drain port (not shown) through the drainage passage 9.

A plurality of drain plates (5) are connected to cover a large floor area. However, when a plurality of drain plates 5 are arranged to cover the bottom slab layer 1 and concrete is laid on the drain plate 5, the pressure of the pouring concrete causes the space between the adjacent drain plates 5 to spread, 1), and the leaked concrete is cured to block the drainage passage (9). In order to prevent clogging of the drainage passage 9, an adjacent drainage plate 5 may be fixed with an adhesive tape (not shown), and concrete may be laid. However, it is very cumbersome and time-consuming to attach and fix the adjacent drain plate with the adhesive tape. Moreover, it is difficult to prevent the expansion of the drain plate due to the concrete pressure only by the adhesive tape alone.

Referring to FIG. 2, the drain plates 100_1 and 100_2 are provided with cups 107, and the drain plates 100_1 and 100_2 are provided at regular intervals And has a plurality of fastening protrusions 111 or a plurality of fastening holes 113 formed therein. The adjacent drain plates 100_1 and 100_2 are aligned so that the plurality of fastening protrusions 111 and the plurality of fastening holes 113 face each other and the fastening protrusions 111 are fitted into the fastening holes 113, 100_2) were connected to each other. The fastening protrusion 111 has a lower surface of the rim of the drain plate 100_1 protruded with a flat upper surface and the fastening hole 113 is a through hole opened to penetrate the end of the fastening protrusion 111.

The drain plates 100_1 and 100_2 are formed by injection molding of a plastic material so as to integrally form not only the cup 107 but also the fastening protrusions 111 and the fastening holes 113 described above. Particularly, in the case of the fastening protrusion 111, it is possible to manufacture the fastening protrusion 111 only by injection molding in order to form the inside of the fastening protrusion 111 to be filled with the plastic material. Therefore, the manufacturing time is relatively long and the production is low and the manufacturing cost is high.

Korean Registered Patent No. 10-0788201 Korean Patent Registration No. 10-0539333

SUMMARY OF THE INVENTION The present invention has been made to solve the problems associated with the conventional drain plate having the above-described injection molding, and it is an object of the present invention to provide a drain plate which is manufactured by a vacuum molding method, .

Another object of the present invention is to provide a drain plate and a method of forming a drain plate in which a plurality of drain plates can be firmly fastened to each other by forming a fastening and fixing structure by a vacuum forming method.

The present invention relates to a thermoplastic resin sheet which is formed integrally with a thermoplastic resin and has flatly extended plates and a plurality of protrusions formed on the plate so as to protrude downward from each other at the same depth, A drain plate having a cup, comprising: a plurality of male couplers disposed on an outer circumferential portion of the plate and projecting downward, for connecting adjacent pair of drain plates; and a male coupler And at least one of a plurality of female couplers which are downwardly fused so as to be fitted, wherein the male coupler and the female coupler both provide a drain board having an upper face formed with a recessed shape and a raised lower face.

Wherein the plate is a quadrangular shape having four straight corners, the plurality of male couplers are arranged along two adjacent straight corners of the four straight corners, and the plurality of female couplers are arranged along the remaining two straight corners .

The thermoplastic resin may be polyethylene terephthalate (PET).

Further, the present invention provides a method of molding the above-mentioned drain pan, comprising the steps of: forming a flat top surface corresponding to the plate, a plurality of cups, and a plurality of shapes corresponding to at least one of the plurality of male couplers and the plurality of female couplers A mold preparing step of preparing a molding mold having an air inlet hole on an inner circumferential surface defining an inner space of the plurality of molding grooves, a step of preparing a molding sheet having a sheet of thermoplastic resin on the upper side of the molding die A heating step of heating and softening the sheet; and a heating step of partially extending the sheet by sucking air through the air intake hole, And a shaping step of sucking the molten metal on the inner circumferential surface of the molding groove of the mold.

The method for molding a drain pan of the present invention may further comprise a curing step for curing the softened sheet after the molding step and an unloading step for separating the cured sheet from the molding die .

In the method for forming a drain pan of the present invention, the curing step and the unloading step may be performed simultaneously by blowing air of room temperature or lower temperature through the air intake holes into the plurality of molding grooves.

The drain plate of the present invention is manufactured not by injection molding but by vacuum molding of a thermoplastic resin sheet to reduce production cost and improve productivity.

Also, the drain plate of the present invention can be formed by vacuum forming the connection protrusions and the connection grooves for connecting the neighboring drain plates to each other, so that the entire drain plate can be manufactured by vacuum molding, thereby reducing the production cost and improving the productivity.

1 is a cross-sectional view schematically showing a construction of a drain pan.
2 is a cross-sectional view illustrating a state where adjacent drain plates are connected to each other according to another conventional example.
3 is a perspective view illustrating a drain pan according to an embodiment of the present invention.
FIGS. 4 and 5 are sectional views sequentially showing the coupling protrusions of one drain plate and coupling grooves of another drain plate when a pair of drain plates according to an embodiment of the present invention are connected to each other.
6 and 7 are sectional views sequentially illustrating a method of forming a drain pan according to an embodiment of the present invention.

Hereinafter, a drain pan according to an embodiment of the present invention and a method of forming the same will be described in detail with reference to the accompanying drawings. The terminology used herein is a term used to properly express the preferred embodiment of the present invention, which may vary depending on the intention of the user or operator or the custom in the field to which the present invention belongs. Therefore, the definitions of these terms should be based on the contents throughout this specification.

FIG. 3 is a perspective view illustrating a drain pan according to an embodiment of the present invention. FIG. 4 and FIG. 5 are views for explaining a method for connecting a pair of drain panes according to an embodiment of the present invention, Are sequentially connected to each other.

Referring to FIG. 3, a drainage plate 10 according to an embodiment of the present invention is used to form a drainage passage for a floor at a construction site. The drainage plate 10 is integrally formed by vacuum forming of a thermoplastic resin a plurality of cups 15, a plurality of male couplers 20 and a plurality of female couplers 25, as shown in FIG.

The thermoplastic resin which is the material of the drain plate 10 may be any material that can be vacuum-formed, such as polyvinyl chloride (PVC), polypropylene (PP), polyethylene (PE) or polyethylene terephthalate ) And a rigid PET are preferable. The plate 11 extends flatly to a constant thickness and has four rectilinear edges along the periphery in a rectangular or square shape with rounded corners.

A plurality of cups (15) are formed on the plate (11) so as to protrude downward from each other at the same depth, and an inner space having an opening on the upper side is formed. The inner space of the cup 15 is defined by the side wall 16 (see FIG. 7) and the bottom 17 (see FIG. 7), and the concrete introduced into the upper opening is received in the inner space, There is no open space other than the upper opening. The cup 15 protrudes downward with respect to the plate 11 by the side wall 16 and the bottom 17 and between the pair of adjacent cups 15 a drain passage 9 ) Is formed.

3 to 5, a plurality of male couplers 20 and a plurality of male couplers 25 are for connecting a pair of adjacent drain plates 10_1 and 10_2, The female coupler 25 is arranged in a line on the outer circumferential portion of the plate 10 along two adjacent straight corners out of the four straight corners of the plate 10 and the other two straight corners of the four straight corners of the plate 10 Are arranged in a line on the outer circumferential portion of the plate 10 along the longitudinal direction. The male coupler 20 is a coupler protruding downward and the female coupler 25 is a coupler downwardly fitted to the male coupler 20. The arrangement of male coupler 20 and female coupler 25 shown in Fig. 3 is merely an example of the present invention. For example, male coupler 20 is arranged on the entire outer peripheral portion of plate 10 Alternatively, female couplers 25 may be arranged on the entire outer circumferential portion of the plate 10.

The horizontal coupler 20 includes a lower side surface 22 formed to protrude downward and a lower side surface 22 formed in a position corresponding to the embossed lower side surface 22, And has an upper surface 21 formed with an engraved surface. Likewise, the female coupler 25 has an upper side 26 formed in a downwardly depressed shape and a lower side 27 formed to protrude downward at a position corresponding to the engraved upper side 26. As a result, the male coupler 20 and the female coupler 25 are formed into similar shapes to each other.

When the male coupler 20 and the male coupler 20 are aligned in a one-to-one correspondence on the male coupler 25 and the male coupler 20 and the female coupler 25 are brought close to each other, The male coupler 20 is fitted to and coupled to the female coupler 25 such that the engraved upper side 26 of the female connector 25 is in close contact with each other so that the adjacent pair of the drain boards 10_1 and 10_2 are connected to each other. The width W_1 and the depth D_1 of the male coupler 20 are set to be slightly smaller than the width W_2 and the depth D_2 of the female coupler 25 so that the male coupler 20 is inserted into the female coupler 25 Or the same. Pressing the male coupler 20 upward and pressing the female coupler 25 downward causes the male coupler 20 and female coupler 20 to move in a direction opposite to the direction of pushing to couple the male coupler 20 and female coupler 25, The pair of drain plates 10_1 and 10_2 connected to each other can be separated again.

6 and 7 are sectional views sequentially illustrating a method of forming a drain pan according to an embodiment of the present invention. Hereinafter, a method of forming a drain pan 10 according to an embodiment of the present invention will be described in detail with reference to these drawings do. The molding method of the drain pan 10 according to the embodiment of the present invention includes a mold preparing step, a loading step, a heating step, a molding step, a curing step, and an unloading step.

Referring to FIGS. 3 and 6 together, the mold preparing step is a step of preparing the molding die 50 for vacuum forming. The molding die 50 has a flat upper side surface 52 corresponding to the plate 11 of the drain plate 10 and a plurality of cups 15 corresponding to the shapes of the spaced apart cups 15, A number of male coupler forming grooves 61 corresponding to the number of male couplers 20 corresponding to the shapes of the plurality of male couplers 20 and a plurality of female couplers 20 Shaped coupler forming grooves 66 corresponding to the shapes of the female couplers 25, as shown in FIG.

A plurality of cup-shaped intake holes 56 are formed in the inner circumferential surface 54 defining the inner space of the cup forming groove 53. Similarly, a plurality of male coupler-formed air intake holes 64 are formed on the inner circumferential surface 62 defining the inner space of the male coupler molding groove 61, and also on the inner peripheral surface 67 of the female coupler molding groove 66 A plurality of female type coupler-formed air intake holes 69 are formed.

In the loading step, a sheet 80 made of a thermoplastic resin such as PET is stacked on the molding die 50 to be supported by the upper side surface 52, So as not to separate from the mold 50. 6, in order to fix the sheet 80 to the molding die 50, the outer peripheral portion of the sheet 80 is closely fixed to the molding die 50 by a tool such as a clamp It is possible. The heating step is a step of heating the sheet 80 fixed to the molding die 50 by a heater 70 to a softening point lower than the melting point and softening the sheet 80.

3 and 7, the forming step is a step of partially drawing the sheet 80 down by sucking air in the direction of the arrow through all the intake holes 56, 64, 69 to form the cup forming groove 53, The male coupler forming groove 61 and the inner circumferential surfaces 54, 62 and 67 of the female coupler forming groove 66, respectively. Concretely, portions supported by the upper surface 52 and separated from the inner surfaces 54, 62, 67 are attracted to the inner peripheral surfaces 54, 62, 67 by a negative pressure, 10, that is, the shape of the cup 15, male coupler 20, and female coupler 25 appear.

The curing step includes curing the softened sheet 80 (see FIG. 6) in which the shape of the cup 15, the male coupler 20 and the female coupler 25 is formed to form the drain plate 10 to be. The unloading step is a step of separating the cured sheet, that is, the drain plate 10 from the molding die 50. 7, the heating is stopped by the heater 70, and air of room temperature or lower temperature is supplied to all of the molding grooves 53, 61, and 66 through all the intake holes 56, 64, The curing step and the unloading step may be performed simultaneously.

On the other hand, the drain pan 10 separated from the molding die 50 can be completed through a trim process after neatly arranging the outer edges. Further, a new sheet 80 (see FIG. 6) is supplied to the blank molding die 50, and a new cycle of the loading step, the heating step, the molding step, the curing step and the unloading step described above proceeds.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the scope of the present invention. Therefore, the true scope of protection of the present invention should be defined only by the appended claims.

10: Drain plate 11: Plate
15: cup 20: male coupler
25: Female coupler 50: Mold for molding
53, 61, 66: forming grooves 56, 64, 69:

Claims

A plurality of cups formed integrally with the thermoplastic resin and having flatly expanded plates and an inner space spaced apart from each other on the plate and having openings on the side of the same depth as the same depth to the lower depth In a drain pan provided with a cup,
A plurality of male couplers disposed on an outer circumferential portion of the plate and protruding downwardly for connecting adjacent pair of drain plates, and a plurality of downwardly female couplers for fitting the male couplers, and at least one kind of coupler,
Wherein the male coupler and the female coupler both have an upper side formed with a depressed shape and a raised lower side formed to be embossed.

The method according to claim 1,
Wherein the plate has a quadrangular shape with four straight corners,
Wherein the plurality of male couplers are arranged along two adjacent straight corners of the four straight corners,
Wherein the plurality of female couplers are disposed along the remaining two straight corners.

The method according to claim 1,
Wherein the thermoplastic resin is PET (polyethylene terephthalate).

A method of molding a drain pan according to any one of claims 1 to 3,
A flat upper surface corresponding to the plate, a plurality of cups, a plurality of molding grooves each having a shape corresponding to at least one of the plurality of male couplers and the plurality of female couplers, A mold preparing step of preparing a molding die having an intake hole on an inner circumferential surface defining an inner circumferential surface thereof;
A loading step of supporting a sheet made of a thermoplastic resin on an upper surface of the molding die and fixing the sheet so as not to separate from the molding die;
A heating step of heating and softening the sheet; And
And a shaping step of partially sucking air through the air intake holes to adsorb the sheet on the inner circumferential surface of the plurality of molding grooves.

5. The method of claim 4,
A curing step of curing the softened sheet after the forming step; And
And an unloading step of separating the cured sheet from the molding die.

6. The method of claim 5,
Wherein the curing step and the unloading step are performed at the same time by blowing air at room temperature or lower temperature through the air intake holes into the plurality of molding grooves.