Corrugated Metal Pipe Single Sheet Width for 3x1 and 5x1 Profiles
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Solution Overview
Problem
Corrugated metal pipe fabricators need to stock multiple sheet widths to accommodate different corrugation profiles, leading to increased inventory costs and inefficiencies, as traditional profiles like 3×1 and 5×1 require separate sheets despite similar structural properties.
Innovation Solution
A single corrugated metal sheet with a sinusoidal cross-sectional profile that allows for the production of both '3×1' and '5×1' profiles using a single sheet width, reducing inventory needs by utilizing a 27¼ inch sheet width, which includes a corrugation pitch of approximately 4½ inches and a height of 1 inch, enabling the fabrication of pipes with diameters between 36 and 216 inches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fabricators stock multiple sheet widths to accommodate different corrugation profiles (3×1 and 5×1), then both profiles can be produced, but inventory costs and complexity increase
Solution Approach 1:
The patent applies universality by designing a single sheet width (27¼ inches) that can produce both 3×1 and 5×1 corrugation profiles through adjustable forming processes. The corrugation profile is determined by forming parameters rather than fixed sheet dimensions, allowing one sheet width to serve multiple production purposes and eliminate the need to stock separate sheet widths for different profiles.
2Strength
If fabricators use traditional 3×1 corrugation profile, then structural strength is adequate, but material usage increases by approximately 10%
Solution Approach 1:
The patent applies parameter changes by modifying the corrugation profile parameters (pitch and depth ratios) to create a 5×1 profile with 10% less material usage. The solution changes the geometric parameters of the corrugations while maintaining structural adequacy, optimizing material efficiency through altered profile dimensions rather than changing the base sheet width.
3Adaptability or versatility
If fabricators stock both 27 inch and 34 inch sheet widths, then both 3×1 and 5×1 profiles can be produced, but inventory costs increase
Solution Approach 1:
The patent eliminates the need to maintain multiple sheet width inventories by making a single 27¼ inch sheet width universal for producing both 3×1 and 5×1 profiles. This reduces inventory quantity while preserving production flexibility, as the same sheet width can be used for different profiles by adjusting forming parameters rather than changing raw material dimensions.
Data Source
AI summary
A metal pipe of single piece includes a wall formed of a single corrugated metal sheet. The sheet has opposing first and second edges extending longitudinally along the sheet. The wall includes a seam formed by abutting portions of the first and second edges. The seam extends helically about and along a length of the wall. The wall has an interior wall side and an opposing exterior wall side. The metal sheet has an interior wall side and an opposing exterior wall side. The interior wall side defines an inner wall surface of the wall, and the exterior wall side defines an outer wall surface of the wall. The sheet has a sinusoidal cross-sectional profile defining 5 corrugation peaks at the inner wall surface and 5 corrugation peaks at the outer wall surface. The sheet has a flattened sheet width of approximately 27¼ inches and a finished sheet width of approximately 23 inches.