Manufacturing method for permeable lid

Abstract

To provide a manufacturing method for producing a permeable lid at a low cost.SOLUTION: A manufacturing method for a permeable lid comprises the steps of: pouring a base-layer aggregate 20 mixed with a binder into a mold 10 corresponding to a shape of the lid and smoothing the base-layer aggregate 20; placing a wire mesh M on the smoothed base-layer aggregate 20; pouring a surface-layer aggregate 30 mixed with the binder onto a base layer and the wire mesh M and smoothing the surface-layer aggregate 30; and removing the permeable lid from the mold 10 after the base-layer aggregate 20 and the surface-layer aggregate 30 are cured, wherein a particle size of the surface-layer aggregate 30 is smaller than a particle size of the base-layer aggregate 20.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to covers for general facilities such as gutters, catch basins, and branch basins, and more particularly to a method for manufacturing water-permeable covers. [Background technology]

[0002] Patent document 1 describes a permeable structure (10) in which aggregates (21, 31) are filled in a space surrounded by a metal edge frame (71) (the symbols in parentheses are those in Patent document 1; the same applies below), and the gaps between the bonded aggregates (21, 31) act as water passages, thereby forming a permeable lid that covers the upper opening of drainage equipment such as a catch basin.

[0003] The permeable structure (10) of Patent Document 1 is divided into a base layer (20) that forms the main part, and a surface layer (30) that is applied on top of the base layer (20) and covers the surface. The aggregate (31) of the surface layer (30) is dry gravel, which is natural stone. The aggregate (21) of the base layer (20) is crushed stone. The aggregates (21, 31) of the surface layer (30) and base layer (20) are respectively solidified with a binder containing ceramic fiber or glass fiber.

[0004] The thickness of the surface layer (30) is 10 mm or less. The particle size of the aggregate (31) of the surface layer (30) is smaller than the particle size of the aggregate (21) of the base layer (20), and is uniformly set to approximately 5 mm. The edge frame (71) includes a metal outer frame (71) and multiple main bars (73) fixed to the outer frame (71). The base layer (20) is anchored to the main bars (73).

[0005] The permeable structure (10) described in Patent Document 1 exhibits high permeability and decorative properties, and can be used as a permeable cover to cover the upper opening of drainage equipment such as a catch basin. The edge frame (71) and base layer (20) provide the necessary strength, while the surface layer (30) provides decorative properties. Leaves and debris are unlikely to enter the surface layer (30), so drainage performance is unlikely to be impaired. There is no risk of shoe heels or stroller wheels getting caught in the surface layer (30). It can prevent pests, mice, mosquitoes, etc. from entering the inside of gutters and catch basins. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Patent No. 6830123 Summary of the Invention [Problem to be solved by the invention]

[0007] The water-permeable lid described in Patent Document 1 is expensive because it uses a metal frame. An object of the present invention is to provide a manufacturing method for producing a water-permeable cover at low cost. [Means for solving the problem]

[0008] In order to solve the above problems, the present invention has the following features. The present invention comprises the steps of pouring aggregate for the base layer, which has been mixed with a binder, into a formwork that matches the shape of the lid, and smoothing the surface; placing a wire mesh on the smoothed aggregate for the base layer; pouring aggregate for the surface layer, which has been mixed with a binder, onto the base layer and the wire mesh, and smoothing the surface; and removing the aggregate for the base layer and the surface layer from the formwork after they have hardened. The particle size of the aggregate for the surface layer is smaller than the particle size of the aggregate for the base layer.

[0009] Preferably, the binder contains fibers mixed therein. Preferably, the fibers are ceramic or glass fibers. Preferably, the binder is made of a urethane resin or an epoxy resin.

[0010] Preferably, a primer is applied to the wire mesh, and then the wire mesh is placed on top of the aggregate for the base layer.

[0011] In one embodiment, the binder may be used in an amount of 3 to 10% by weight relative to the weight of the aggregate for the base layer or surface layer.

[0012] Preferably, the wire mesh is fitted with a removal fitting.

[0013] Preferably, a release agent is applied to the mold.

[0014] Preferably, the corners of the water-permeable lid removed from the formwork are chamfered and a binder is applied to the chamfered portions.

[0015] In one embodiment, the aggregate for the surface layer is decorative gravel, and the aggregate for the base layer is No. 6 crushed stone, and the surface layer is thinner than the base layer. [Effects of the Invention]

[0016] According to the present invention, the wire mesh is sandwiched between the aggregate for the base layer and the aggregate for the surface layer, and the entire structure hardens. Since the particle size of the aggregate for the surface layer is smaller than that of the aggregate for the base layer, the aggregate for the surface layer hardens while entangled with the wire mesh and the aggregate for the base layer. After hardening, the contact areas between adjacent aggregates are bonded, and the remaining areas are voids, resulting in a water-permeable lid. Wire mesh is easily available and can be simply cut to the appropriate size, allowing for the production of a low-cost water-permeable lid.

[0017] If fibers, especially ceramic fibers or glass fibers, are mixed into the binder, strong adhesion can be achieved. Also, if a urethane resin or epoxy resin is used as the binder, strong adhesion can be achieved.

[0018] Applying a primer to the wire mesh will ensure more reliable adhesion of the wire mesh to the aggregate for the base and surface layers.

[0019] By keeping the binder weight at 3 to 10%, reliable adhesion can be achieved without using excessive binder, thereby reducing costs.

[0020] When a water-permeable lid is used in a general meeting hall, the water-permeable lid can be easily removed using the removal fittings attached to the wire mesh.

[0021] By applying a release agent to the formwork, the water-permeable lid can be easily removed from the formwork after hardening.

[0022] Applying a binder to the chamfered area can prevent damage to the corners.

[0023] By using decorative gravel as the aggregate for the surface layer and No. 6 crushed stone as the aggregate for the base layer, and making the surface layer thinner than the base layer, an inexpensive yet highly decorative permeable cover can be provided.

[0024] These and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0025] [Figure 1] FIG. 1 is a flowchart showing the manufacturing process of a water-permeable cover according to one embodiment of the present invention. [Figure 2] FIG. 2 is a photograph showing an embodiment of the formwork 10. In FIG. [Figure 3]FIG. 3 is a photograph substituted for a drawing showing an embodiment in which aggregate 20 to be used in the base layer is poured into a formwork 10 and smoothed. [Figure 4] FIG. 4 is a photograph in place of a drawing showing an embodiment in which a crack-preventing wire mesh M with a removal metal fitting K attached is placed. [Figure 5] FIG. 5 is a photograph showing an example in which aggregate 30 used in the surface layer is poured. [Figure 6] FIG. 6 is a photograph showing an example in which the surface layer aggregate 30 is smoothed. [Figure 7] FIG. 7 is a photograph showing an example of a completed water-permeable cover. [Figure 8] FIG. 8 is a photograph, substituted for a drawing, showing a cross section of the water-permeable cover of the example. [Figure 9] FIG. 9 is a photograph, substituted for a drawing, of an enlarged cross section showing an example of the state of adhesion between aggregates. DETAILED DESCRIPTION OF THE INVENTION

[0026] The flow of a method for manufacturing a water-permeable cover according to one embodiment of the present invention will be described with reference to FIG. First, the aggregate 20 to be used in the base layer is weighed (S101). The thickness of the base layer is determined appropriately taking into consideration strength, permeability, etc., and is set to, for example, 20 mm to 60 mm. The amount of aggregate 20 to be used is determined by the volume of the base layer according to the thickness. As the aggregate 20 used in the base layer, for example, No. 6 crushed stone with a particle size of 5 to 13 mm may be used, but the present invention is not limited to this.

[0027] Next, the aggregate 30 to be used in the surface layer is weighed (S102). The thickness of the surface layer is determined appropriately taking into consideration the strength, permeability, surface decorativeness, etc., and is set to, for example, 10 mm to 20 mm. The amount of aggregate 30 to be used is determined by the volume of the surface layer according to the thickness. As the aggregate 30 used in the surface layer, decorative gravel of 5 mm to 10 mm may be used, for example, but is not limited to this in the present invention.

[0028] A binder with a predetermined weight ratio for each aggregate is prepared (S103). For example, a binder made of urethane resin mixed with fine glass fibers of about 1 mm is used. As a product, "Fiber U" manufactured by Fine Kogyo Co., Ltd. (headquarters: Takatsuki City, Osaka Prefecture) is recommended, but is not limited to this. Furthermore, the length of the mixed fibers is not limited to about 1 mm. The fibers to be mixed may be glass fibers, ceramic fibers, or other fibers. Furthermore, the curable resin may be an epoxy resin in addition to a urethane resin. The predetermined weight ratio in S103 is preferably about 5% of the weight of the aggregate, but is not limited thereto, and may be 3 to 10%.

[0029] Next, a form is prepared and installed (S104). For example, as shown in Figure 2, form 10 may be installed in the area corresponding to the lid of the water collection basin. In the case of mass production, it is advisable to prepare a large number of formworks that match the shape of the lid.

[0030] Next, a release agent is applied to the formwork (S105). Mineral oil or the like may be used as the release agent, but there is no limitation thereto. By applying the release agent to the formwork, it becomes possible to easily remove the water-permeable lid from the formwork after the binder has hardened.

[0031] Next, the base layer aggregate and binder are mixed and poured into a formwork and smoothed with a metal trowel (S106). The aggregate and binder are thoroughly mixed so that the binder adheres to the surface of the aggregate (and so on). Figure 3 is a photograph of the base layer aggregate 20 after it has been smoothed. At this time, by pressing and smoothing the aggregate 20 with the metal trowel, the aggregate 20 is bonded to each other with appropriate gaps.

[0032] Next, a primer is applied to the crack-prevention wire mesh to which the removal fittings are attached (S107). As shown in Figure 4, the metal wire mesh M is cut to fit the size of the lid. Here, the wire mesh used is the same as that used for concrete floors, but the type of wire mesh is not limited. As shown in FIG. 4, a metal fitting K is attached to the wire mesh M. Any type of primer can be used, but it is advisable to use a primer that enhances adhesion between the urethane resin and the metal wire mesh.

[0033] A wire mesh coated with a primer to prevent cracking is placed on top of the base layer (S108, Figure 4).

[0034] Next, the aggregate and binder of the surface layer are mixed together (S109).

[0035] The surface layer aggregate mixed with a binder is poured onto the base layer and the crack-preventing wire mesh (S110). Figure 5 is a photograph showing the state at this time. Since the particle size of the aggregate 30 is smaller than the particle size of the aggregate 20 in the base layer, the surface layer aggregate 30 can be leveled so that it becomes entangled and adheres tightly between the wire mesh and the aggregate 20 in the base layer (S110). The surface of the surface layer is smoothed by pressing with a metal trowel (S110, Figure 6). By carrying out the work in this manner, the aggregate 30 becomes entangled in the gaps between the aggregate 20 and the wire mesh and adheres to them.

[0036] After hardening and curing for a predetermined time (for example, 24 hours), the water-permeable lid is removed from the formwork (S111). Figure 7 shows the water-permeable lid in the removed state.

[0037] Then, to prevent the corners from chipping and cracking, the corners are chamfered (S112), and the same binder is applied to the chamfered corners to complete the water-permeable lid (S113, Figure 7).

[0038] A photograph of the completed permeable cover cut lengthwise is shown in Figure 8. As shown in Figure 8, wire mesh M is embedded between the base layer and the surface layer, but because the particle size of aggregate 30 in the surface layer is smaller than the particle size of aggregate 20 in the base layer, aggregate 30 and wire mesh M are intertwined and adhered to the base layer.

[0039] As shown in Figure 9, there are many voids 2 between the aggregates, even though the closely spaced portions 1 are bonded together by the binder. Therefore, water flows downward through these voids.

[0040] Since the particle size of the surface layer is small, the size of the voids is also small, so that debris larger than the voids cannot penetrate into the surface layer and can be removed by sweeping with a broom or the like. The grain size of the base layer is large, so the pores in the base layer are large. Therefore, small debris that passes through the pores in the surface layer can also pass through the pores in the base layer. Therefore, by spraying water from above the surface layer using a high-pressure water washer, the permeability can be restored.

[0041] Since the wire mesh is tightly adhered between the base layer and the surface layer, the completed water-permeable cover will not crack, at least when subjected to human load.

[0042] Wire mesh is readily available and can be cut to various sizes for use, so this embodiment can provide a low-cost water-permeable lid.

[0043] Although the present invention has been described in detail above, the above description is merely illustrative of the present invention in all respects and is not intended to limit its scope. It goes without saying that various improvements and modifications can be made without departing from the scope of the present invention. Each of the constituent elements of the invention disclosed in this specification is considered to be an independent, stand-alone invention. Inventions that combine the constituent elements in any manner are also included in the present invention. The specific expressions in this specification are merely examples, and the present invention also includes those that conceptualize these exemplary expressions. [Industrial Applicability]

[0044] The present invention is a method for manufacturing a water-permeable lid and is industrially applicable. [Explanation of symbols]

[0045] 1 Adhesive part 2 void 10 Formwork 20 Aggregate for base layer 30 Surface aggregate M Wire Mesh K Removal bracket

Claims

1. The process involves pouring the base layer aggregate mixed with the binder into a form that matches the shape of the lid and smoothing it out. placing a wire mesh on the smoothly leveled aggregate for the base layer; a step of pouring the surface layer aggregate mixed with the binder onto the base layer and the wire mesh and smoothing the surface layer; and removing the aggregate for the base layer and the aggregate for the surface layer from the formwork after the aggregate for the base layer and the aggregate for the surface layer have hardened. A method for manufacturing a water-permeable lid, characterized in that the particle size of the aggregate for the surface layer is smaller than the particle size of the aggregate for the base layer.

2. The method for manufacturing a water-permeable lid according to claim 1, wherein the binder contains fibers mixed therein.

3. 3. The method for manufacturing a water-permeable cover according to claim 2, wherein the fibers are ceramic fibers or glass fibers.

4. 3. The method for manufacturing a water-permeable lid according to claim 1, wherein the binder is made of a urethane resin or an epoxy resin.

5. 2. The method for manufacturing a water-permeable lid according to claim 1, wherein a primer is applied to the wire mesh, and then the wire mesh is placed on the aggregate for the base layer.

6. 2. The method for manufacturing a water-permeable lid according to claim 1, wherein the binder is used in an amount of 3 to 10% by weight relative to the weight of the aggregate for the base layer or surface layer.

7. 2. The method for manufacturing a water-permeable lid according to claim 1, wherein a metal fitting for removal is attached to the wire mesh.

8. 2. The method for manufacturing a water-permeable lid according to claim 1, wherein a release agent is applied to the formwork.

9. 2. The method for manufacturing a water-permeable lid according to claim 1, further comprising chamfering corners of the water-permeable lid removed from the formwork, and applying the binder to the chamfered corners.

10. The aggregate for the surface layer is decorative gravel, The aggregate for the base layer is No. 6 crushed stone, The method for manufacturing a water-permeable lid according to claim 1, wherein the surface layer is thinner than the base layer.

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