Corrugated Pile Sheet Floor for Gravity Separator
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Solution Overview
Problem
The high material costs, particularly steel, in constructing gravity separator units due to the need for substantial material to withstand water pressure without significant bending or sagging, and the inefficiency in sludge collection and removal processes.
Innovation Solution
A gravity separator unit with a floor composed of corrugated pile sheets featuring alternating tops and parallel gutters, which reduces material usage by up to 50% while maintaining structural integrity, and a scraping device with adjustable blades to efficiently collect and remove sludge through sidewall openings without requiring additional floor openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a substantial amount of steel material is used to construct the container floor to withstand water pressure, then structural integrity is maintained, but material costs and weight increase significantly
Solution Approach 1:
The patent applies corrugated profile sheets with curved alternating peaks and valleys instead of flat sheets. The curved geometry inherently resists water pressure through its shape, distributing loads more effectively and reducing the need for thick material. This allows using thinner sheets (1-5 mm) while maintaining structural integrity, thereby reducing material consumption and costs.
2Quantity of substance
If the floor is made from thin corrugated sheets to reduce material usage, then material costs decrease, but structural strength and resistance to water pressure may be compromised
Solution Approach 1:
The corrugated profile with alternating peaks and valleys creates a structurally efficient geometry that resists water pressure. The curved surfaces distribute hydrostatic loads across the entire structure, allowing thin sheets (1-5 mm) to achieve sufficient strength without requiring thick solid plates, thus reducing material consumption while maintaining integrity.
Solution Approach 2:
The floor is segmented into multiple corrugated sheets arranged in parallel, each contributing to the overall structural strength. This segmentation allows the load to be distributed across multiple independent structural elements rather than requiring a single thick plate, achieving both material reduction and structural adequacy.
3Ease of manufacture
If traditional flat floor designs are used, then construction is simple, but sludge collection and removal requires additional complex mechanisms
Solution Approach 1:
The corrugated floor structure serves dual functions: it provides structural support against water pressure and simultaneously creates gutters for sludge collection and removal. The valleys of the corrugated profile naturally channel sludge toward collection points, eliminating the need for separate sludge removal mechanisms and simplifying the overall system while reducing device complexity.
4Ease of operation
If openings are made in the floor for sludge removal, then sludge can be discharged, but structural integrity and water-tightness are compromised
Solution Approach 1:
Instead of making openings in the floor for sludge removal, the invention inverts the approach by having the corrugated floor structure itself channel sludge through its valleys to collection points on the sidewalls or at the ends. This eliminates the need for floor openings, preserving structural integrity and water-tightness while enabling effective sludge discharge through the gutter system.
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
The corrugated floor design reduces material consumption while maintaining structural integrity, and the scraping device effectively collects and removes sludge without additional floor openings, enhancing operational efficiency and reducing maintenance needs.
Implementation Method 1
the floor is constructed from a plurality of corrugated pile sheets which define a plurality of alternating tops and parallel gutters
Implementation Method 2
the scraping device is adapted for moving the scraping elements along the gutters in a direction towards an end of the gutters with each of the one or more scraping blades thereof extending at least partially in a corresponding gutter
Implementation Method 3
jet nozzles arranged for ejecting jets of water into the gutters in a direction parallel to the longitudinal direction of the gutters
Implementation Method 4
a gravity separator unit comprising a container for holding at least 1 m³ of water to be treated
Data Source
Figure 1A~1B
Figure 2A
Figure 2B
AI summary
A gravity separator unit, such as a dissolved air flotation (DAF) or a sedimentation unit, comprising a container (10) having sidewalls (11,12,13,14) and a floor (20), wherein the floor comprises one or more corrugated pile sheets (21,22,23) which define a plurality of alternating tops (32,34,36) and parallel gutters (31,33,35,37) facing the interior of the container, wherein the tops and lower portions of the gutters are vertically spaced apart by a distance (h) of between 3 and 30 cm from each other. The gravity separator unit is preferably provided with scraping elements with scraping blades which are arranged for pushing sludge collected in the gutters along the longitudinal direction of the gutters, and/or with jet nozzles for ejecting water into the gutters in order to push the sludge along the longitudinal direction of the gutters. A method for manufacturing a gravity separator unit with a floor comprising one or more corrugated pile sheets is disclosed as well.