Modular Manhole Base Assembly with Internal Liner
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Solution Overview
Problem
Existing manhole base structures are costly, complex to produce, and not compatible with pre-existing equipment due to their individualized form sets, which are expensive and not adaptable to variable pipe geometries, leading to inefficiencies in fluid transfer systems.
Innovation Solution
A modular manhole base assembly with a non-cylindrical, low-volume concrete base lined with a polymer or fiberglass liner, allowing for flexible configuration and production on-site, reducing inventory and operational complexity, and compatible with existing structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom individualized forms are used for each manhole base geometry, then manufacturing precision for specific geometries is improved, but device complexity and inventory requirements increase
Solution Approach 1:
The patent applies universality by designing a single modular form assembly that can produce multiple different manhole base geometries through reconfiguration. The form assembly includes interchangeable components (sides, ends, corners) that can be arranged in different combinations to create various pipe aperture configurations, eliminating the need for separate custom forms for each geometry while maintaining manufacturing precision
Solution Approach 2:
The form assembly is segmented into discrete modular components including sides, ends, and corners that can be independently selected and reconfigured. This segmentation allows the same basic components to be assembled in different arrangements to produce different manhole base geometries, reducing inventory complexity while preserving the ability to manufacture precise custom configurations
2Ease of manufacture
If precast cylindrical concrete structures are used, then ease of manufacture is improved, but adaptability to varying pipe angles and elevations deteriorates
Solution Approach 1:
The patent applies dynamics by creating a form assembly that can be dynamically reconfigured for different geometries. The modular components can be assembled and disassembled to adapt to varying pipe angles, elevations, and aperture arrangements, allowing the same basic form system to produce diverse manhole base configurations without requiring separate precast cylindrical structures for each geometry
3Manufacturing precision
If large coring machines are used to drill holes in cast concrete structures, then manufacturing precision for fluid channels is improved, but device complexity and cost increase
Solution Approach 1:
The patent applies preliminary action by forming the fluid channels as integral parts of the manhole base during the initial concrete casting process, rather than drilling them afterward. The modular form assembly includes components that define the fluid channel geometry, allowing channels to be cast directly into the concrete in the correct positions and configurations, eliminating the need for subsequent coring operations
Solution Approach 2:
The patent merges the formation of the manhole base structure and the fluid channels into a single integrated casting operation. The modular form assembly simultaneously defines both the external geometry and the internal fluid channel pathways, combining what would otherwise be separate manufacturing steps into one unified process that reduces equipment complexity and overall manufacturing complexity
Data Source
AI summary
A manhole base assembly and a method for making the same employ a non-cylindrical, low-volume concrete base that is fully lined to protect the concrete against chemical and physical attack while in service. This lined concrete manhole base assembly may be readily produced using a modular manhole form assembly which can be configured for a wide variety of geometrical configurations compatible with, e.g., varying pipe angles, elevations and sizes. The form assembly is configurable to provide any desired angle and elevation for the pipe apertures to interface with various underground systems, and can be formed on-site to facilitate compatibility with existing structures. The assembly provides for flexible, modular construction of a wide variety of lined manhole base assemblies at minimal cost, reduced concrete consumption and reduced operational complexity. The modular nature of the production form assembly also facilitates reduced inventory requirements when various manhole base assembly geometries are needed.