Multi-Wall Corrugated Pipe Vacuum Forming
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Solution Overview
Problem
The existing methods for manufacturing multi-wall corrugated polymer pipes face challenges in creating three-wall pipes with sufficient strength for large diameter applications, particularly in achieving a water-tight seal and efficient assembly, which is complex and requires numerous tools and man-hours, often resulting in joint failures and misalignment.
Innovation Solution
A system and method involving an extruder to co-extrude concentric annular tubes, a corrugator to form dual-wall pipes, a cross-head die to extrude an outer wall onto the corrugated wall, and a vacuum punch to deform the outer wall inward, creating a three-wall pipe with improved bonding and assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional coupling methods (bell and spigot, external reinforcement) are used to assemble plastic pipe sections, then the pipe sections can be joined together, but the assembly process becomes complex requiring many tools and man-hours, and joint failures and misalignment still occur
Solution Approach 1:
The patent integrates the coupling mechanism directly into the pipe manufacturing process by forming bell and spigot portions as integral parts of the pipe sections during extrusion. This merging of the coupling function into the pipe structure itself eliminates the need for separate coupling devices and complex assembly tools, while ensuring reliable joints through precise factory-formed geometries
Solution Approach 2:
The bell and spigot portions are pre-formed during the pipe manufacturing process before the pipe sections are transported to the installation site. This preliminary formation of coupling features ensures precise geometry and alignment, eliminating the need for complex field assembly operations and reducing the risk of misalignment and joint failures
2Strength
If external reinforcement means (straps, brackets, wraps) are added to strengthen pipe joints, then joint strength is improved, but the device complexity and installation time increase
Solution Approach 1:
The patent combines the structural pipe wall and joint reinforcement into a single integrated three-wall construction. The intermediate corrugated wall serves simultaneously as the pipe structure and the joint reinforcement, eliminating the need for separate external reinforcement elements like straps and brackets
Solution Approach 2:
The patent employs a composite three-wall construction with an inner smooth wall, an intermediate corrugated wall, and an outer smooth wall. This composite structure provides inherent strength and rigidity to both the pipe body and joints, eliminating the need for additional external reinforcement
3Manufacturing precision
If precise and careful excavation and installation are performed to avoid misalignment, then joint alignment is improved, but the installation time and labor requirements increase
Solution Approach 1:
The bell and spigot portions are pre-formed during manufacturing with precise geometries and tolerances. This preliminary precision work ensures that field assembly requires minimal adjustment and alignment effort, significantly reducing installation time while maintaining high alignment accuracy
Solution Approach 2:
The patent employs curved, tapered bell and spigot geometries that guide alignment during assembly. The curved surfaces naturally accommodate minor misalignments and guide the spigot into proper positioning within the bell, reducing the need for precise manual alignment while ensuring proper joint formation
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 solution enables the production of stronger, three-wall corrugated polymer pipes with enhanced bonding between layers, simplifying the assembly process and reducing the need for additional reinforcement, thus improving installation efficiency and reducing material and labor costs.
Implementation Method 1
a vacuum punch configured to penetrate the outer wall of pipe and draw a vacuum between the corrugated wall and the outer wall, such that the outer wall of pipe deforms inward toward the corrugated wall of pipe
Data Source
AI summary
A system is disclosed for manufacturing multi-wall corrugated polymer pipe. The system includes an extruder configured to co-extrude concentric annular tubes; a corrugator configured to form the concentric annular tubes into a dual-wall pipe having a smooth wall and a corrugated wall; a cross-head die configured to extrude an outer wall of pipe onto the corrugated wall of the dual-wall pipe; a vacuum punch configured to penetrate the outer wall of pipe and draw a vacuum between the corrugated wall and the outer wall, such that the outer wall of pipe deforms inward toward the corrugated wall of pipe between bell and spigot portions of the corrugated wall; and a cutter configured to cut the pipe into sections where the vacuum punch deformed the outer wall between the bell and spigot portions of the corrugated wall. A method of manufacturing multi-wall corrugated polymer pipe is also disclosed.