Interlocking Drain Grate Structure for Rigidity
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Solution Overview
Problem
Conventional drain covers made from sheet metal grates with limited slot width suffer from reduced rigidity due to material thickness constraints, leading to increased costs when stronger materials are used to enhance rigidity.
Innovation Solution
The solution involves interlocking multiple grates, where the struts of one grate are inserted into the slots of another, doubling the side face height and slot width, thereby increasing rigidity without increasing material thickness, and connecting them via edge folds or U-shaped support strips for enhanced stability and a single-piece handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the slot width is limited to maintain a simple grate structure, then the manufacturing is easier, but the side face height is reduced which decreases rigidity
Solution Approach 1:
Multiple grates are nested within each other, with the second grate positioned inside the first grate. The struts of the second grate are inserted into the slots of the first grate, creating a nested configuration that effectively doubles the side face height and increases rigidity without requiring a single complex grate structure
Solution Approach 2:
The solution transitions from a single-plane grate structure to a multi-layered three-dimensional configuration. By stacking grates in the vertical dimension and interlocking them through slot insertion, the effective height is doubled while maintaining the simplicity of individual grate components
2Strength
If stronger material is used to increase rigidity, then the grate strength is improved, but the manufacturing costs increase significantly
Solution Approach 1:
The grate system is segmented into multiple separate grate components that are interconnected. Instead of using a single thick or strong material grate, the system uses multiple standard-thickness grates with reduced individual slot widths, combining them to achieve the required rigidity at lower material cost
Solution Approach 2:
The solution creates a composite grate structure by combining multiple standard grates into an interlocked assembly. This composite configuration achieves enhanced rigidity equivalent to stronger materials but uses conventional materials, thereby reducing manufacturing costs
3Strength
If multiple grates are interconnected to increase rigidity, then the overall structure becomes more rigid, but the device complexity increases
Solution Approach 1:
Multiple separate grate components are merged into a single interconnected assembly through the slot insertion mechanism. The struts of inner grates are inserted into the slots of outer grates, creating a unified rigid structure that functions as a single unit while maintaining the simplicity of individual components
Data Source
AI summary
Covers for drains, manholes or similar constructions are known which comprise a first grate (10) made of sheet metal and comprising slots (11) and struts (12), said struts having top faces (13) and each strut having side faces (14, 14′) made of sheet metal bent with respect to the top face. In order to increase the rigidity it is proposed that at least a second grate (20) is provided, the struts (22) of which are inserted in the slots (11) of the first grate (10).