Air Plenum Crack Sealing via Positive Pressure

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Solution Overview

Problem

Conventional methods for sealing air plenum boxes in wastewater treatment facilities are ineffective due to improper sealing, allowing air leakage and structural damage from high pressure air, which reduces oxygen delivery to wastewater and exacerbates cracks in concrete surfaces.

Innovation Solution

A method and system that introduce a sealant into the air plenum box and apply positive pressure to urge the sealant into cracks, using a cover with a seal member and a positive pressure source to inhibit external gas entry and ensure the sealant is pressed into the cracks, combined with a spray assembly to apply the sealant under maintained pressure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high pressure air is used to aerate wastewater, then oxygen delivery to wastewater is improved, but cracks in concrete surfaces expand causing structural damage

Engineering Contradiction:

Improveoxygen deliveryVSAvoidconcrete structure

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The patent applies sealant to cracks in the air plenum box before pressurization, and uses backer rods to preliminarily fill and protect crack openings. This preliminary sealing action prevents crack expansion during subsequent high-pressure operation, allowing the system to maintain both structural integrity and high oxygen delivery capability

Inventive Principle:

Principle #10Preliminary action

2Reliability

If sealant is applied to cracks in air plenum box, then air leakage is prevented, but leaking air from adjacent tanks displaces sealant before curing

Engineering Contradiction:

Improveseal effectivenessVSAvoidsealant application

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent introduces positive pressure into the air plenum box before applying sealant, creating a pressure barrier that prevents external air from adjacent tanks from entering and displacing the sealant. This preliminary pressure establishment counteracts the harmful air leakage effect before sealant application, ensuring proper sealant adhesion and curing

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The patent uses backer rods as intermediary elements inserted into cracks before sealant application. These rods serve as a physical barrier and support structure that prevents sealant displacement while allowing the sealant to bond properly to the concrete surfaces, facilitating effective sealing despite challenging conditions

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If positive pressure is introduced into air plenum box, then sealant is urged into cracks for effective sealing, but external pressurized gases may enter through cracks during pressurization

Engineering Contradiction:

Improvesealant placementVSAvoidexternal gas entry

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent introduces positive pressure into the air plenum box before sealant application and maintains it during the process. This preliminary pressure establishment creates an outward pressure barrier that prevents external pressurized gases from entering through cracks, while simultaneously urging the sealant into crack openings for effective sealing

Inventive Principle:

Principle #9Preliminary anti-action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Effectively seals cracks in air plenum boxes, preventing air leakage and structural damage, ensuring consistent oxygen delivery to wastewater and extending the lifespan of the facilities by ensuring the sealant is properly applied and cured.

Implementation Method 1

introducing a positive pressure into the air plenum box of a pressure selected so that cracks between the air plenum box and the surrounding environment are also pressurized to inhibit entry of pressurized gasses from the surrounding environment from entering the air plenum box during the pressurization process via the cracks

Methodology Applied

Scientific EffectPositive pressure: Pressure Increase

Implementation Method 2

introducing a sealant into the air plenum box; introducing a positive pressure into the air plenum box of a pressure selected so that the sealant is urged into the cracks by the pressure

Methodology Applied

Scientific EffectPressure-driven flow: Pressure Increase

Data Source

PatentUS7837906B1Systems and methods for treating air chambers in aeration basins of wastewater treatment facilities

Publication Date: 2010.11.23 PPG INDUSTRIES OHIO INC

AI summary

An air plenum tank comprising a plurality of outlets aerate and agitate wastewater in a liquid treatment facility through the use of high pressured air creating cracks on the floor of the air plenum tank. Advantageously, the cracks are sealed using a system and method comprising isolating and positively pressurizing the air plenum tank and then sealing the tank using a sealant compound.