Corrugated Stormwater Chamber Sub-Corrugation and Interlocking Design
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Solution Overview
Problem
Existing molded plastic chambers for stormwater detention lack efficiency in water reception and dispersion, particularly in developed sites, due to inadequate structural features and connectivity options.
Innovation Solution
A plastic arch-shaped corrugated chamber with transverse corrugation crests and valleys, featuring sub-corrugation features, stiffening fingers, and a viewport structure, along with methods for producing chambers with unitary or open ends, and connecting them end-to-end to form elongated rows, enhancing structural integrity and installation flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional molded plastic chambers are used for stormwater detention, then installation is straightforward, but water reception and dispersion efficiency is insufficient
Solution Approach 1:
The chamber is divided into multiple corrugation crests and valleys that segment the water flow path, creating multiple reception and dispersion zones simultaneously. This segmentation increases the effective surface area for water interaction without proportionally increasing the overall chamber volume, thereby improving water reception and dispersion efficiency while maintaining reasonable structural complexity.
Solution Approach 2:
The corrugation features extend in the transverse dimension across the chamber, creating a three-dimensional flow distribution system. The sub-corrugation features on the crests and valleys add another layer of dimensional complexity that enhances water distribution patterns, allowing efficient water reception and dispersion through multi-dimensional flow paths rather than simple linear channels.
2Adaptability or versatility
If chambers are connected end-to-end to form elongated rows, then installation flexibility increases, but structural integrity at connection points may be compromised
Solution Approach 1:
The corrugation crests and valleys at adjacent chamber ends are designed to overlap and merge structurally when chambers are connected end-to-end. The sub-corrugation features on the end corrugations create interlocking patterns that strengthen the connection points, allowing multiple chambers to form a continuous, structurally integrated elongated row while maintaining installation flexibility.
3Strength
If sub-corrugation features are added to corrugation crests and valleys, then structural strength increases, but manufacturing complexity increases
Solution Approach 1:
The sub-corrugation features are pre-formed as integral parts of the corrugation crests and valleys during the single-shot molding process. By designing the mold cavities to include the sub-corrugation geometry from the outset, the structural strengthening features are created simultaneously with the main chamber structure, avoiding post-manufacturing operations and maintaining ease of manufacture while achieving enhanced structural strength.
Data Source
AI summary
A plastic, corrugated open bottom chamber includes features such as one or more of (i) sub-corrugation features on corrugation crests and/or corrugation valleys, (ii) stiffening fingers on the bottom of chamber foot portions, (iii) a viewport configuration that intersects only a single corrugation crest and (iv) a unitary end wall. A method of producing chambers with or without a unitary end wall using a common mold tool is also provided. A method of interconnecting chambers to form a chamber rows is also provided.