RU2689725C1 - Method of manufacturing overflow chute element - Google Patents

Abstract

FIELD: construction.SUBSTANCE: invention relates to construction and can be used in construction of swimming pools. Method consists in forming an l-shaped cross-section profile by injecting melt of first thermoplastic material into mold and forming a strap on the upper flange of the l-shaped cross-section profile by forcing the melt of the second thermoplastic material into the mold so that the above upper flange is immersed into the second thermoplastic material, wherein the profile and the strap are mutually connected.EFFECT: higher reliability of lattice element structure under action of dynamic loads in conditions of swimming pool.4 cl, 5 dwg

Description

TECHNICAL FIELD

The present invention relates to the field of construction and can be used in the construction of swimming pools. In particular, the invention relates to gratings for overflow gutters of swimming pools.

BACKGROUND

The removal of the upper level of the water through the overflow gutter due to its indisputable advantages is a prerequisite for the construction of modern pools.

The grill of the overflow gutter must meet a number of requirements, in particular, it must pass the water flowing into the gutter and be absolutely reliable and hygienic at the same time, and also it should be pleasant to the feet and harmoniously combined with the design of the entire pool.

The prior art lattice element overflow gutter disclosed in the patent DE 19616792 C1 (08/14/1997, E03F 5/06). The known lattice element is made of plastic by injection molding. For the formation of the lattice elements are connected to each other by means of elastic parts that are attached to their ends. The lattice element is made in the form of a T-shaped element, the shelf of which is located in the upper part of the lattice element. On the upper side of the shelf, grooves are made that extend at an angle of 90 ° to each other, which provides resistance to sliding along the grid of people's legs, as well as a water barrier when water moves in the longitudinal direction of the strip. However, water that is retained in these grooves of the gutter element will lead to the gradual destruction of the lattice element, as well as the development of undesirable microorganisms in these grooves.

The prior art also describes the overflow chute element, disclosed in patent EP 1245758 B1 (02.10.2002, E04C 2/42, E04H 4/12). A known lattice element comprises a plurality of transverse plates connected by longitudinal plates, one of which passes through the centers of the transverse plates, and the other connects their ends. At the same time, on each transverse plate there is a strap arranged perpendicular to the plate, i.e. parallel to the edge of the pool. In addition, one edge of each transverse plate is made in the form of a protrusion, and the other edge of the transverse plate contains a recess. The connection of the elements of the lattice occurs by inserting the protrusion into the corresponding recess. The grille is made of plastic, each element of which is made in one piece.

From the patent ES 2073982 B1 (August 16, 1995, E04C 2/42, E04H 4/12, E04H 4/14) a lattice element is known, on two opposite sides of which there are elastic fingers, with fingers from one side containing pins, and fingers with the other hand contain recesses. The lattice element is made of plastic.

A disadvantage of the known technical solutions to patents EP 1245758 B1 and ES 2073982 B1 is that the lattice elements have a complex configuration, which implies a low manufacturability of the design. In addition, the complex configuration of the elements of the lattice increases the complexity of the Assembly of the grid overflow chute of these elements of the lattice. Additionally, the surface of the lattice elements is made of plastic, which is quickly destructible, and also has a low slip resistance, especially when water gets into it, which is unsafe when using the overflow chute.

Another known grating element of the overflow gutter is disclosed in patent FR 2,715,425 B1 (07/28/1995, Е04С 2/42, Е04Н 4/12). As in the above documents, in this patent, the lattice element provides the possibility of assembling a smoothly bending lattice. The assembly is due to the fastening of each element of the lattice on one longitudinal bar. Also, on the surface of the lattice element, a plurality of transverse curving planks extending beyond the transverse edge is made integrally with it, which increases the slip resistance. However, the design feature of leaving the transverse bending slats beyond the transverse edge, i.e. connecting a bending bar with a transverse rib to only a part of the bottom surface, leaving the rest of the bending bar beyond the transverse rib without a support, leads to the formation of a brittle structure of the lattice element, which is subject to rapid destruction, in particular, the formation of chips on the ribbed surface and scratches on the entire surface of the lattice.

From the patent RU 68020 (10.11.2007, E03F 5/06), an element of the overflow chute lattice is known, which is made in the form of an I-beam profile having a metal coating on the upper shelf. The profile is made of polypropylene, and the metal coating is formed by crimping the top shelf of the profile with a strip of stainless steel. However, in the process of performing the crimping of the profile, considerable pressure is applied to it, as a result of which damage may occur, which may become apparent only during the operation of the lattice element. In addition, the metal surface does not provide sufficient resistance to sliding, especially when water gets on its surface. Thus, the known element of the lattice does not ensure the safety of operation in a swimming pool.

The closest analogue of the present invention is a lattice element, disclosed in patent RU 2599557 (10.10.2016, E03F 5/06). The known lattice element of the overflow gutter contains a T-shaped section profile and an overlay of composite material containing a groove and mounted on the wall of the T-shaped section profile on the side opposite to the shelf of this profile by inserting the wall into this groove. In one of the embodiments of the lattice element fastening the lining to the profile is carried out with the use of glue.

A disadvantage of the known lattice element overflow gutter is the possibility of its easy disassembly, which can lead to rapid destruction of the lattice element during operation. The use of glue when installing the nozzle on the profile also does not provide high structural strength, since during operation the grille is under constant mechanical action and moisture, which will lead to a gradual destruction of the joint. Thus, the known construction of the lattice element is subject to rapid destruction, which is unsafe during operation.

Thus, the known elements of the lattices of overflow gutters do not provide a high resistance to destruction, in addition, the upper surface of the elements of the lattices do not have a high slip resistance in a swimming pool, which is unsafe during operation. In this case, the known elements of the lattices have a complex structure, which complicates the manufacturing process and the process of assembling the grating of the overflow trough.

Thus, the object of the present invention is to provide an element of the overflow gutter with high structural strength.

DISCLOSURE OF THE INVENTION

This problem is solved thanks to the grid element of the overflow gutter containing an I-beam profile made of the first thermoplastic material and an overlay made of the second thermoplastic material mounted on the upper shelf of the I-beam profile and connected to it together with the whole by means of injection molding.

As a result of the implementation of the proposed grating element of the overflow gutter, a technical result is provided in the form of increasing the reliability of the construction of the grating element of the overflow gutter under the influence of dynamic loads in a swimming pool.

The technical result is achieved due to the fact that the profile of the I-section and the lining, forming the element of the overflow trough lattice, are integrally formed by injection molding.

In addition, the implementation of the profile and lining of the lattice element at the same time whole by injection molding ensures their reliable adhesion and eliminates the destruction of the lattice element, in particular the separation of the profile and lining during operation, which reduces the risk of injury. Also, the implementation of the profile and lining in one piece eliminates the gap in the connection between the profile and the lining, which serves as a breeding ground for the reproduction of microorganisms and phytoplankton. In addition, the implementation of the profile and lining at the same time the whole by injection molding eliminates the possibility of structural damage during its manufacture and further destruction during its operation.

In one embodiment, the first thermoplastic material may be a plastic, and the second thermoplastic material may be a composite material. Due to the plastic profile, high resistance to dynamic loads is provided, which prevents its destruction, and the execution of the composite lining reduces the likelihood of chips and scratches, which degrade the performance of the overflow chute element and its hygienic properties.

According to one embodiment, longitudinal grooves can be made on opposite lateral sides of the upper flange, and the pad covers said grooves and is adjacent to them.

According to another embodiment, holes can be made on the profile wall, located directly below the upper shelf and evenly distributed along the entire profile length, while the pad covers these holes and passes through them. Due to the implementation of grooves and / or holes on the profile, an enhanced adhesion of the lining to the profile is ensured, which increases the reliability of the connection of the profile and the lining and, consequently, the resistance of the grating element to dynamic loads.

This problem is also solved due to the method of manufacture by injection molding of the grid element of the overflow gutter containing an I-section profile from the first thermoplastic material and an overlay from the second thermoplastic material, including forming an I-section profile by forcing the melt of the first thermoplastic material into a mold; and molding the overlay on the top shelf of the I-beam profile by injecting the melt of the second thermoplastic material into a mold so that the upper shelf is immersed in the second thermoplastic material, and the profile and the overlay are interconnected.

Due to the use of the injection molding technology for the production of the lattice element, a high technological effectiveness of the lattice element of the overflow chute is ensured by reducing the number of operations, eliminating manual labor, as well as reducing production time, for example, in comparison with the lattice element, the design of which is obtained by fit with the lining and profile .

In one embodiment, longitudinal grooves are made on opposite sides of the upper flange, and when molding the lining, said grooves are immersed in a second thermoplastic material.

According to another embodiment, holes are made on the profile wall, located directly below the upper shelf and evenly distributed along the entire profile length, and when molding the lining, these holes are immersed in the second thermoplastic material.

According to another embodiment, sanding the lining is performed.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is explained in more detail in non-limiting examples of its implementation with reference to the accompanying drawings, in which:

FIG. 1 depicts a general perspective view of a grating element of an overflow gutter with an overlay according to one of the embodiments of the present invention;

FIG. 2 shows a general perspective view of a grating element of an overflow gutter without a lining according to an embodiment of the present invention shown in FIG. one;

FIG. 3 is a cross-sectional view of the profile of a grating element of the overflow channel without a lining in accordance with an embodiment of the present invention shown in FIG. one;

FIG. 4 is a partial cross-sectional view of the profile of a grating element of a overflow channel with an overlay according to an embodiment of the present invention shown in FIG. one;

FIG. 5 is a side view of the profile of a grating element of an overflow trough without a lining according to an embodiment of the present invention shown in FIG. one.

IMPLEMENTATION OF THE INVENTION

The proposed element of the lattice is designed for use in the lattices of overflow gutters of swimming pools.

A preferred embodiment of the grating element of the overflow channel is shown in FIG. 1. The lattice element contains a profile 1 of I-section made of the first thermoplastic material, and an overlay 2 located on the top shelf 3 of the profile (FIG. 2) and made of the second thermoplastic material. The plate 2 is connected to the upper shelf 3 by means of injection molding (FIG. 3).

Materials for the manufacture of the lattice element is chosen on the basis of their compatibility, chemical resistance and wear resistance, as well as the possibility of operating in ambient conditions. In addition, the choice of materials for the manufacture of the lattice element must take into account the requirements of GOST R 53491.2-2012 “Pools. Water preparation. Part 2. Safety Requirements ”, according to which the materials of the surfaces in contact with the pool water should be resistant to its aggressive impact and should not have a negative impact on it in the process of water preparation and / or serve as a breeding ground for the reproduction of microorganisms and phytoplankton.

Based on these requirements, in the present invention, the profile 1 is made of plastic, for example, polypropylene, and the lining 2 is made of composite material.

The choice of these materials is dictated by the fact that plastic is a durable material suitable for making parts from it by injection molding. Plastic has a low sensitivity to moisture, which makes it possible to use it in a swimming pool. However, the manufacture of the lattice element completely made of plastic is impractical, since This material is prone to chipping and scratching. Therefore, to perform the lining choose a composite material, which will reduce the likelihood of chips and scratches, deteriorating the performance of the element overflow trough and its hygienic properties.

The combined use of these materials allows you to create a compound characterized by durability and long service life.

On each of the opposite sides of the upper flange 3, longitudinal grooves 4 (FIG. 3) can be made, with the pad 2 completely covering said grooves 4 and adjacent to their surface. The implementation of these grooves allows you to increase the strength of the connection of the lining 2 with the shelf 3. The shape of the grooves 4 is chosen in such a way as to ensure the optimal parameters of the connection lining and profile.

The profile 1 can be additionally equipped with holes 5, made on the wall 6 of the profile in the immediate vicinity of the upper flange 3 and uniformly distributed in the longitudinal direction along the length of the profile 1, as shown in FIG. 5. When this lining 2 when placed on the top shelf 3 of the profile 1 overlaps the holes 5 and passes through them, which increases the strength of the connection lining 2 with the profile 1.

At opposite ends of the profile 1 on the side of the connection with the lining 2 there are ledges 7 formed by a cut of the upper shelf 3 that are not covered by the lining 2. Due to the presence of the ledges 7, when installing the grating assembled from the grid elements into the overflow chute of the pool, a gap is formed between the lining 2 elements of the lattice and the wall of the gutter. As a result, the bulk of the water falling into the overflow gutter from the pool flows down the gutter wall, without falling on the pad. Thus, the lining 2 in most cases remain dry, which reduces the likelihood of slipping users' feet, and, consequently, the likelihood of injury as a result of a fall.

The corners 8 of the lining 2 are preferably rounded (FIG. 4), which reduces their abrasion and the formation of chips.

The lattice element is preferably provided with connecting means, intended for the connection are located near the lattice elements. The connecting means comprise a first connecting element 9 located on one side of the wall 6 and having a protrusion 10, and a second connecting element 11 located on the other side of the wall 6 and having an opening 12 responding to said protrusion 10 (see FIG. 1-3).

The protrusion 10 and the hole 12 can have such a shape and size that when they are connected, the grating elements are placed at a certain angle to each other, and, accordingly, the possibility of a smooth bending of the overflow chute grid (not shown in the drawings). In particular, the opening 12 may be narrowed inward, and the protrusion 10 may have a corresponding narrowing towards its end.

The lattice element is preferably obtained using the technology of multi-component injection molding. The preferred option for multi-component injection molding technology is sequential casting.

To implement the proposed method, an injection mold with a sprue is used, which is made with the possibility of successive formation of profile 1 with grooves 4, holes 5, ledges 7, as well as with connecting elements 10 and 12, and lining 2 with the formation of an integral lattice element.

It is possible to realize the proposed shape of the lattice element by, for example, automatically expanding the injection molding cavity with movable punches.

In the first stage of the method, an I-section profile 1 is made by injecting a melt of the first thermoplastic material using an injection unit into the injection mold, in particular into the molding cavity of the injection mold.

At the second stage, the punch is displaced during the hardening of the plastic in order to create free space for forming the lining 2 around the upper flange 3 of profile 1, and the melt of the second thermoplastic material is injected into the mold so that the upper shelf 3 of the profile is completely immersed in the second thermoplastic material. The second thermoplastic material is adjacent to the surface of the grooves 4 and passes through the holes 5.

After the molding of the lining 2 is completed, the obtained lattice element of the overflow trough is allowed to cool and remove from the mold.

The proposed method has high manufacturability, provided by minimizing the time and money spent in assembling the lattice element. Moreover, the possibility of producing a lattice element by means of multi-component casting on one installation eliminates the need to move parts when performing different technological processes, which leads to savings in moving the product between installations, eliminating time lost during assembly and saving production space.

The proposed grating element of the overflow gutter can also be made by multi-component injection molding with the transfer of the workpiece.

At the same time, in the first stage, an I-section profile 1 is made by injecting the melt of the first thermoplastic material into the cavity of the first mold, followed by cooling. While the mold is made in such a way that it allows you to form on the profile 1 of the groove 4, the holes 5, ledges 7, as well as the connecting elements 9 and 11.

Next, the resulting profile 1 is removed from the first mold and transferred to the second mold, in which the lining 2 is molded by injecting the second thermoplastic material so that the upper shelf 3 with the grooves 4 and the holes 5 are in the melt field. After forming the lining 2, the resulting lattice element is cooled and removed from the mold. The extraction and transfer of the profile 1 and the entire lattice element can be carried out both manually and by automatic means.

The composite material used to make the lining 2 can be chosen in such a way that the surface structure of the lining 2 directly after molding will mimic the structure and appearance of the stone surface.

To improve the safety of use and make the element of the lattice aesthetic look, excess material can be removed from its surface. Additionally, to roughen and increase slip resistance, the pad 2 can be sanded using a grinding tool, such as metal brushes or sanding paper.

When this grinding tool can be selected in such a way that the surface of the lining 2, processed with it, will have a structure and appearance, simulating the structure and appearance of a wooden surface.

The grating of the overflow trough is obtained by successively connecting the grating elements by placing the projection 10 of the connecting element 9 of one grating element in the hole 12 of the connecting element 11 of the adjacent grating element.

Grid overflow trough according to the present invention is suitable for overflow gutters pools, made in the form of a groove around the perimeter of the pool to collect the splashing water from the pool. Such a gutter contains ledges on both sides, the dimensions of which are specified by regulatory documents, in particular GOST R 53491.1-2009 “Pools. Preparation of water. Grid overflow trough is installed on the overflow gutter, leaning the ends of the lattice elements on the ledges of the overflow gutter. In the private implementation, the height of the ledge of the overflow gutter corresponds to the total height of the grid element of the overflow gutter. Thus, after installing the grate on the overflow gutter, it is located flush with the edge of the pool.

In another embodiment, the implementation in the case of increasing the height of the ledge may increase the thickness of the lining without changing the size of the profile to ensure an increase in the overall height of the grid element. In addition, in case of damage to the lattice element with a thicker lining wall and after repeated surface treatment of the lining by grinding, such a lattice element can be used in the construction of overflow chutes with a lower height of the ledges, provided that its level after installation on the overflow chute is at pool edge. Thus, improved structural and operational properties of the elements of the overflow gutter are provided.

It should be noted that the described device is only one of the preferred embodiments of the invention. It is obvious to a person skilled in the art that changes and modifications may be made to the present invention without departing from the scope of the invention as defined by the following formula.

Claims (6)

1. A method of manufacturing a lattice element overflow chute containing the I-profile of the first thermoplastic material and the lining of the second thermoplastic material, injection molded, including: forming an I-section profile by injecting the melt of the first thermoplastic material into a mold and molding the lining on the top shelf of an I-section profile by injecting a melt of the second thermoplastic material into a mold so that said upper shelf is immersed in the second thermoplastic material, and the profile and the lining are interconnected. 2. The method according to claim 1, according to which longitudinal grooves are made on opposite sides of the upper flange, and when molding the lining, said grooves are immersed in a second thermoplastic material. 3. The method according to claim 1, according to which holes are made on the profile wall, located directly below the upper shelf and evenly distributed along the entire profile length, and when molding the overlay, these holes are immersed in a second thermoplastic material. 4. The method according to any one of claims 1 to 3, according to which perform the grinding lining.

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