Hinged Flat-Pack Utility Vault for Toolless On-Site Assembly
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Solution Overview
Problem
Existing underground utility enclosures are bulky, time-consuming to assemble, and costly for shipping and storage due to their two-piece construction requiring mechanical fasteners and sealants.
Innovation Solution
A vault design with hinged or hooked side panels that lay flat for shipping and storage, using interlocking hooks and over-center clamps for toolless assembly, and a lid retention system with hooks and spring-loaded latches for secure closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional two-piece vault construction with mechanical fasteners and sealants is used, then structural strength and sealing are improved, but assembly time and labor intensity increase significantly
Solution Approach 1:
The vault is divided into multiple flat panels that can be independently manufactured and shipped, then assembled on-site through interlocking mechanisms without requiring traditional mechanical fasteners
Solution Approach 2:
The panels incorporate self-aligning and self-securing features through molded-in interlocking mechanisms that automatically engage when panels are positioned together, eliminating the need for external fastening tools and operations
2Reliability
If traditional mechanical fasteners and sealants are used to join vault halves, then connection reliability is improved, but device complexity and inventory requirements increase
Solution Approach 1:
The fastening and sealing functions are merged into a single integrated molded interlocking mechanism that is formed as part of the panel structure itself, eliminating the need for separate fasteners and sealant applications
Solution Approach 2:
The interlocking mechanisms are self-contained within the panel structures, with no external fasteners or sealants required, simplifying the overall system while maintaining connection reliability
3Strength
If vault components are molded in one or two pieces for structural integrity, then strength is improved, but shipping and storage costs increase due to size and bulkiness
Solution Approach 1:
The vault structure is segmented into multiple flat panels that can be nested or stacked during shipping, dramatically reducing the volume required for transport and storage while maintaining full structural integrity when assembled
Solution Approach 2:
The panels are designed to collapse from a three-dimensional vault structure into a two-dimensional flat configuration for shipping, optimizing space utilization without compromising the structural strength when reassembled
4Stability of the object's composition
If traditional vault assembly methods are used, then structural stability is achieved, but productivity and installation efficiency decrease
Solution Approach 1:
The interlocking mechanisms are pre-formed and integrated into the panel structures during manufacturing, so that on-site assembly simply requires positioning panels together rather than performing complex fastening operations
Solution Approach 2:
The panels automatically align and secure themselves through the molded interlocking features, eliminating the need for tools, fasteners, or sealants and dramatically increasing assembly speed while maintaining structural stability
Data Source
AI summary
An underground utilities vault having side panels and a lid, the side panels each include a side wall section and an end wall section that are hinged together such that the side panels lay flat for shipping and storage and then when assembled comprise a side wall and an end wall perpendicular to one another at a hinge point, and wherein the side panels include a plurality of clamps for connecting the side panels together.