# Patent

## Title
Corrugation structure for pipe

## Abstract

A corrugated pipe 2 has a plurality of corrugation structures 10, 12 positioned adjacent one another. The corrugation structures 10, 12 comprise an inner cylindrical wall 22, two annular wall portions 28, 32 that extend outwardly from the inner cylindrical wall 22, and a bowed annular wall portion 40 that is connected to the outer ends 36, 38 of the two annular wall portions 28, 32. The corrugation structure 10, 12 includes a centroid 48, 49 and at least a portion of the inner surface 50 of the bowed wall portion 40 has a radius R1 centered on the centroid 48, 49 and at least a portion of the outer surface 52 of the bowed wall portion 40 has a radius R2 centered on the centroid 48, 49. The cavity 56 defined by the corrugation structure 10, 12 has an inner surface with an inner radius R1, R3 that is equal to or greater than one half the thickness T1 of the inner cylindrical wall 22. The profile of the corrugation structure 10, 12 is configured to optimally accept forces caused by backfill soil positioned over the pipe 2. A method of manufacturing a corrugated pipe 2 includes manufacturing a first, a second, and a third corrugated pipe 80, 90, 100, with each pipe having an inner diameter ID and an outer diameter OD. The inner diameter ID is chosen such that the first pipe 80 can be telescopically inserted into the second pipe 90 and the second pipe 90 can be telescopically inserted into the third pipe 100. A method of shipping a plurality of different diameter pipes is also provided.

## Background
This application is a continuation of U.S. application Ser. No. 10/468,089, filed Feb. 23, 2004 (now U.S. Pat. No. 6,840,285), which is a 371 of PCT/US02/10619, filed Apr. 4, 2002, which claims the benefit of U.S. Provisional Application Ser. No. 60/281,441, filed Apr. 4, 2001.


FIELD OF THE INVENTION
The claimed invention relates to a corrugated pipe. In particular, the invention relates to a corrugation structure for a corrugated pipe.
BACKGROUND OF THE INVENTION
Corrugated pipes are oftentimes made of a synthetic material that is generally intended for underground use where a high pressure must be withstood. Such pipes are typically used for water main pipes, sewer pipes, drain pipes, electric and telephone cable conduits, and the like. In installing pipes underground, the pipes are positioned in trenches and then covered with a backfill soil
SUMMARY
According to the invention, a corrugated pipe having a longitudinal axis comprises a plurality of corrugation structures positioned adjacent one another to form a portion of the corrugated pipe. Each corrugation structure includes a cylindrical wall centered on the longitudinal axis and an annular U-shaped wall extending from the cylindrical wall. The U-shaped wall has a thickness that is uniform or substantially uniform throughout the length thereof.
The invention also concerns a corrugation structure for a corrugated pipe having a longitudinal axis. The corrugation structure comprises an inner cylindrical wall centered on the longitudinal axis, two annular wall portions that extend outwardly from the cylindrical wall, and an annular bowed wall portion. Each of the outwardly extending wall portions have a radially outer end. The annular bowed wall portion extends axially between the radially outer ends of the two annular wall portions, The bowed wall portion has an inner surface and an outer surface, with the two annular wall portions and the annular bowed wall portion together defining an outer wall that is connected to the inner cylindrical wall. The corrugation structure also includes a centroid defined by the corrugation structure. At least a portion of the inner surface of the bowed wall portion has a radius centered on the centroid, and at least a portion of the outer surface of the bowed wall portion has a radius centered on the centroid.
The invention also relates to a corrugation structure for a corrugated pipe having a longitudinal axis. The corrugation structure is symmetric about a plane that is perpendicular to the longitudinal axis of the corrugated pipe and comprises an inner cylindrical wall, two annular wall portions, and a bowed wall portion. The inner cylindrical wall is centered on the longitudinal axis of the corrugated pipe and has a wall thickness at the plane of symmetry. The two annular wall portions extend outwardly from the cylindrical wall and are spaced from one another, with each outwardly-extending wall having a radially outer end. The bowed annular wall portion extends axially between the radially outer ends of the two annular wall portions. A cavity is bounded by the inner cylindrical wall, the outwardly extending wall portions and the bowed wall portion. The cavity has an inner surface, and the inner surface has at least one inner radius, with the inner radius being equal to or greater than one half the thickness of the inner cylindrical wall at the plane of symmetry.
The invention also concerns a corrugation structure for a corrugated pipe having a longitudinal axis. The annular wall portions have an outer surface, with each outer surface having an outer surface end point at the radially outer end thereof. The curved wall portion also has an outer surface. A peak point is located on the outer surface of the curved wall portion at the radially outermost point thereof relative to the longitudinal axis. An angle formed between a line extending from the peak point to the outer surface end point of the annular wall portions relative to the longitudinal axis is a function of a natural slip angle.
The invention further relates to a corrugated pipe having a longitudinal axis that comprises first and second corrugation structures positioned adjacent a plurality of corrugation structures to form a portion of the corrugated pipe. The first and second corrugation structures are positioned adjacent one another and centered on the longitudinal axis of the corrugation structure. Each of the first and second corrugation structures are symmetrical about a plane that is perpendicular to the axis. In addition, each of the first and second corrugation structures comprises a cylindrical wall centered on the axis. Two annular wall portions extend outwardly from the cylindrical wall at spaced locations relative to one another. The annular wall portions have outer ends and outer surfaces, and an annular curved wall portion extends axially between the outer ends of the annular wall portions. The annular curved wall portion has an outer surface. The corrugation structure also includes first and second centroids of the first and second corrugations, and a centroid line extends between the first and second centroids. The corrugation structure further includes first and second points of intersection of the centroid line with the outer surfaces of the annular wall portions of the first and second corrugation structures. A first line extends from the first point of intersection toward the second corrugation structure and is tangent to the outer surface of the annular curved wall portion of the second corrugation structure. The first line is at a first angle relative to the longitudinal axis that is equal to or greater than a predetermined natural slip angle. A second line extends from the second point of intersection towards the first corrugation structure and is tangent to the outer surface of the annular curved wall portion of the first corrugation structure. The second line is at a second angle relative to the longitudinal axis that is equal to or greater than the predetermined natural slip angle.
The invention also relates to a method of manufacturing a corrugated pipe which includes manufacturing a first, a second and a third corrugated pipe, each pipe having an inner diameter and an outer diameter. The inner and outer diameters of the pipes are chosen such that the first pipe can be telescopically inserted into the second pipe and the second pipe can be telescopically inserted into the third pipe.
The invention further concerns a method of shipping a plurality of different diameter pipes comprising providing a plurality of pipes each having a different inner and outer diameter from the other pipes. The plurality of pipes includes at least a smaller diameter pipe, an intermediate diameter pipe and a larger diameter pipe. The smaller diameter pipe has an outer diameter that is smaller than the inner diameter of the intermediate diameter pipe, and the intermediate diameter pipe has a smaller outer diameter than the inner diameter of the larger diameter pipe. The method also includes telescopically inserting the intermediate diameter pipe inside the larger diameter pipe to form bundled pipes, and telescopically inserting the smaller diameter pipe inside the intermediate diameter pipe to form bundled pipes. The method further includes the step of shipping the bundled pipes to a destination.



BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a side view of a corrugated pipe according to the invention;
FIGS. 2 and 3 are a partial cross-sectional view of the corrugated pipe of FIG. 1, showing two corrugation structures positioned adjacent one another in the wall of the pipe; and
FIG. 4 is an end and a side perspective view of another aspect of the invention, showing multiple diameter pipes inserted inside one another for shipping purposes.



DETAILED DESCRIPTION
The present invention utilizes a corrugation profile on a corrugated pipe 2 that is designed to maximize the structural integrity in an installed environment and minimize the material requirements utilized to manufacture the pipe. The natural slip angle of common backfill soils is considered in conjunction with the profile dimensions of the corrugation structure of the corrugated pipe to enhance the structural performance of the profile structure, as will be discussed in conjunction with FIGS. 1–3 below.
The invention relates to a corrugation structure located among a series of corrugation structures 10, 12 positioned adjacent one another to form a corrugated pipe 2. As shown in FIGS. 1 and 2, the corrugated pipe has a longitudinal axis 20 around which the corrugation structures 10, 12 are positioned. The corrugation structures 10, 12 are cylindrical and are centered on the longitudinal axis 20 of the pipe 2. Each corrugation structure 10, 12 comprises a profile that includes an inner cylindrical wall or liner 22 and an outer annular U-shaped wall 24 extending outwardly from the inner cylindrical wall 22. The U-shaped wall 24 has a thickness T5 that is preferably uniform or substantially uniform throughout the length of the wall 24. The outer wall 24 and inner wall 22 together define a cavity 56 in the interior of the corrugation structure.
Each U-shaped wall 24 of the corrugation structure 10, 12 includes two annular straight wall portions 28, 32 and a bowed or curved wall portion 40. The straight wall portions 28, 32 are spaced from each other and are positioned on opposite sides of the U-shaped wall 24. The bowed wall portion 40 extends axially between the outer ends of the straight walls 28, 34 such that the straight walls 28, 32 and the bowed wall 40 together form the U-shaped wall 24. Each straight wall portion 28, 32 extends outwardly from the inner cylindrical wall 22 in a generally radial or transverse manner while the bowed wall is oriented in a generally parallel manner to the longitudinal axis 20 of the pipe 2. The straight walls 28, 32 have a common thickness T3 that is preferably uniform throughout the length of the straight walls 28, 32. The bowed wall 40 has a thickness T4 that is preferably uniform throughout the length of the bowed wall 40, and that is substantially equal to the thickness T3 of the straight walls 28, 32. Uniform material distribution throughout the interior of the corrugation structure will provide a uniform cross sectional area. Elimination of material thickness and dimensional thickness variations will improve the corrugation profile stability.
The corrugation structure 10, 12, as shown in FIG. 2, includes an outer diameter OD and an inner diameter ID, both of which are measured from the longitudinal axis 20 of the pipe 2. The corrugation structure profile has a crown or peak point 60 that is positioned at the radially outermost point of the bowed wall portion 40. A height of the corrugation structure profile is measured between the inner most surface of the inner cylindrical wall 22 and the peak point 60 of the corrugation structure 10, 12. The neutral axis NA of the corrugation structure 10, 12 profile is positioned at the centroid 48, 49 of the corrugation structure. The pitch or frequency of the corrugation structures 10, 12 is the length L2 of each individual structure.
The corrugation structure profile is symmetric about a plane 44, 46 that is perpendicular to the longitudinal axis 20 of the pipe 2. A portion of the inner surface 50 of the bowed wall 40 has a radius R1 centered on the centroid 48, 49 (neutral axis NA). Likewise, a portion of the outer surface 52 of the bowed wall 40 has a radius R2 centered on the centroid 48, 49 (neutral axis NA).
The inner cylindrical wall 22 has a thickness T1 at the plane of symmetry 44, 46 and a length L1. The cavity 56 of the corrugation structure 10, 12 has an inner surface 58 with several inner surface radiuses, such as R1 and R3. In order to insure proper dispersion of local stresses so that stress risers are reduced at the transition points between the various wall portions, all of the inner surface radiuses are preferably equal to or greater than one half the thickness T1 of the inner cylindrical wall 22.
The thickness of each corrugation structure profile component is based on an interdependent relationship with four performance criteria, including: 1) maximum burial depth; 2) resistance to hydraulic compression; 3) a 30% yield test criteria; and 4) AASHTO M294 mandated QC check testing requirements. All dimensions of the corrugation profile are related to these performance criteria by the moment of inertia, cross-sectional area, and location of the neutral axis. Other performance criteria are discussed in further detail below.
In use, the corrugated pipe 2 may be positioned in a trench and covered with any of a variety of backfill soils. Each backfill soil has a natural slip angle. Slip angle is directly related to the loads, and thus the actual moments and stresses, that are applied to a pipe structure during use. In particular, slip angle is directly related to the angle at which loads are applied to the corrugation structure's surface. A “maximum slip angle” is the greatest slip angle among the variety of backfill soils that the corrugation structures are expected to be covered with. Similarly, a “minimum slip angle” is the lowest slip angle among the variety of backfill soils that the corrugation structures are expected to be covered with. Natural soil slip angle will generally range from a minimum of about 28° to a maximum of about 37.5° for soil types that are more generally encountered. However, the natural soil slip angle may vary from these angles depending upon the type of fill material utilized to cover the pipe 2.
According to one aspect of the invention, the corrugation structure profile is designed such that the shape of the bowed wall 40 is a function of the natural slip angle of the backfill soil. The profile geometry, as shown in FIG. 3 (Feature C), is designed so that the bowed wall portion 40 of the corrugation structure 10, 12 profile when loaded at the peak point 60 by a force vector Fsoil slip at the minimum slip angle of soil β forms a maximum resisting moment Ms1 on the straight side wall 28, 30 at outer surface end point 36, 38. In particular, referring to FIG. 2, the profile shape is configured so that the peak point 60 is aligned with an outer surface point 36, 38 at each of the radially outer ends of the straight side walls 28, 32 at an angle β. The angle β is a function of the natural slip angle of backfill soil. Preferably, the angle β is approximately equal to the minimum slip angle of the soil utilized with the particular corrugated pipe 2, in order to maximize the stability of the corrugation under load.
According to another aspect of the invention, the position and shape of each corrugation profile relative to the adjacent profile is also a function of the natural soil slip angle. The frequency of the corrugations (or pitch as defined FIG. 2) is specifically located such that a maximum slip angle will have a vector force Fsoil slip (as illustrated in FIG. 3; Feature F) at or above the neutral axis of the corrugation profile. This vector force is based upon an interface with the tangent of the bowed wall portion 40, where friction is at a minimum, with the origin point 72, 74. Locating the force Fsoil slip at this location will result in a stable profile. In addition, the stability of the corrugation profile is enhanced by an optimized angle between the side walls of the profile and a vertical axis. When force is vertically applied to the corrugation structure at the peak point, the side wall portions 28, 32 are oriented such that they can withstand the vertical force so that the corrugation structure does not collapse.
In particular, with reference again to FIG. 2, first 10 and second 12 corrugation structures are shown positioned adjacent one another and centered around the longitudinal axis of the corrugated pipe 2. Each of the straight side walls 28, 32 of the U-shaped wall 20 has an outer peripheral surface 64 and bowed wall 40 has an outer peripheral surface 68. As discussed above, the corrugation profiles have a centroid 48, 49, which defines the location of the neutral axis NA of the corrugation profile. A centroid line 70 is shown to extend between the centroids 48, 49. The centroid line 70 intersects the radially-extending peripheral surfaces 64 of the first and second corrugation structures at first and second points of intersection 72 and 74.
The corrugation structure profiles are configured such that a first straight line 76 extends from the first point of intersection 72 on the first corrugation structure 10 and is tangent to the bowed peripheral surface 68 of the second corrugation structure 12. The first line 76 has a first angle α1, relative to the longitudinal axis 20 of the pipe, that is equal to or greater than a predetermined natural slip angle of backfill soil. Likewise, a second straight line 78 extends from the second point of intersection 74 on the second corrugation structure 12 and is tangent to the bowed peripheral surface 68 of the first corrugation structure 10. The second line 78 has a second angle α2, relative to the central axis 20, that is equal to or greater than the predetermined natural slip angle. Specifically, the angles α1 and α2 are equal to or greater than the maximum slip angle for the corrugated pipe and are preferably equal to one another. By utilizing appropriate spacing of the corrugations (or pitch), as prescribed by lines 76 and 78, the maximum potential for slip results in a minimum lateral soil load at or above the neutral axis of the sidewall of the corrugated profile.
According to another aspect of the invention, stress concentration may also be minimized on the corrugations by controlling the wall radius inside the corrugation profile, as shown in FIG. 3 (Feature D). Feature D illustrates the area of the corrugation structure 10, 12 that is oftentimes most prone to problems associated with stress concentration. The radius R3 on the interior of the corrugation cavity 56 is unique to the inventive profile. This radius is preferably equal to or greater than one half the thickness T1 of the inner cylindrical wall 22.
The above-described corrugation profile design utilizes the natural soil slip angle in conjunction with the geometric design to enhance the performance of the corrugation profile. In addition, the corrugation profile design allows for minimized material thicknesses, while creating a structurally stable profile under hydraulic and compressive soil loads. The design reduces surface defects that ensures watertight gasket sealing, and the provision of a smooth radius on the interior of the profile assists in eliminating stress risers. In one embodiment, liner thickness and widths are specifically designed to withstand hydraulic loading at 10.8 psi.
According to another aspect of the invention, the corrugation structure is configured in order to allow for maximum shipping potential. In particular, shipping costs associated with the shipping of corrugated pipes is very high, primarily because a lot of dead space is found inside the pipes that is not currently utilized and the pipes themselves takes up a lot of space. One aspect of the present invention utilizes this dead space in the interior of the pipes to ship smaller diameter pipes. For instance, as many as 14 or more different diameter pipes may be shipped at one time in a single bundle by utilizing the present invention. Typical diameters of pipes that are utilized in the industry include 4′′, 6′′, 8′′, 10′′, 12′′, 15′′, 18′′, 24′′, 30′′, 36′′, 42′′, 48′′, 54′′, and 60′′ pipes, among others. According to the invention, the outside diameter of each size of pipe is designed such that it will fit into each larger size pipe. This is done by designing the size of the corrugation to provide a degree of clearance so that the smaller size pipe may easily be inserted into and removed from the larger diameter pipe. Therefore, the profile design in combination with the dimensions of the various diameter pipes minimizes shipping costs since multiple diameter pipes may be shipped in a single bundle.
An example of this is shown in FIG. 4, where first 80, second 90 and third 100 diameter corrugated pipes 2 are depicted. Each pipe 2 has an inner diameter ID and an outer diameter OD that is different from the other. The inner diameter ID and outer diameter OD of each pipe are chosen such that the first pipe 80 can be telescopically inserted into the second pipe 90, and the second pipe 90 can be telescopically inserted into the third pipe 100. This allows for the smallest diameter pipe 80 to be inserted inside the middle diameter pipe 90. And the middle diameter pipe 90 may be inserted inside the largest diameter pipe 100, which results in reducing cost and size in shipping of the pipes. Thus, the diameters and corrugation profiles of the pipes are preferably configured in this manner to assist in shipping.
In a preferred embodiment, the pipe 2 is made of a structurally stable HDPE (high density polyethylene). The corrugated pipe profile is capable of withstanding hydraulic, axial, longitudinal, soil and ring bending loads. The inventive profile maximizes structural integrity and stability while minimizing the material. While a preferred material is HDPE, other types of materials may also be utilized in forming the pipes of the present invention, such as other types of polyethylene or plastics.
While various features of the claimed invention are presented above, it should be understood that the features may be used singly or in any combination thereof. Therefore, the claimed invention is not to be limited to only the specific embodiments depicted herein.
Further, it should be understood that variations and modifications may occur to those skilled in the art to which the claimed invention pertains. The embodiments described herein are exemplary of the claimed invention. The disclosure may enable those skilled in the art to make and use embodiments having alternative elements that likewise correspond to the elements of the invention recited in the claims. The intended scope of the invention may thus include other embodiments that do not differ or that insubstantially differ from the literal language of the claims. The scope of the present invention is accordingly defined as set forth in the appended claims.

## Claims

1. A corrugated pipe having a longitudinal axis comprising:
a plurality of corrugation structures positioned adjacent one another to form a portion of the corrugated pipe, the corrugation structures being centered on the longitudinal axis of the corrugated pipe, each corrugation structure comprising:
a cylindrical wall centered on the longitudinal axis, the cylindrical wall having a radially outer edge; and
an annular U-shaped wall extending from the cylindrical wall, the U-shaped wall comprising:
two annular straight walls that are spaced from each other and that extend outwardly from the cylindrical wall, each straight wall having a radially outer end and a radially inner end; and
a bowed wall extending axially between the radially outer ends of the two annular straight walls,


wherein the shape of the annular U-shaped wall of each corrugation structure and the distance between adjacent corrugation structures are a function of a natural soil slip angle of a preselected backfill soil.

2. The corrugated pipe of claim 1, wherein the function relating the shape of the annular U-shaped wall to the natural soil slip angle comprises:
the angle of a line drawn from the peak of the bowed wall to an exterior corner of the radially outer end of at least one of the annular straight walls is equal to the natural soil slip angle of the backfill soil.

3. The corrugated pipe of claim 2, wherein at least two preselected backfill soils are utilized and the angle of the line drawn from the peak of the bowed wall to an exterior corner of the radially outer end of the at least one annular straight walls is equal to the smallest natural soil slip angle of the at least two preselected backfill soils.

4. The corrugated pipe of claim 1, wherein the function relating the distance between adjacent corrugation structures to the natural soil slip angle comprises:
a line tangent to the bowed wall of a corrugation structure with an angle equal to the natural soil slip angle of the preselected backfill soil will intersect an adjacent corrugation structure at about or above a neutral axis defined between a centroid of the corrugation structure and a centroid of the adjacent corrugation structure.

5. The corrugated pipe of claim 4, wherein the plurality of corrugation structures have a fixed pitch.

6. The corrugated pipe of claim 4, wherein at least two preselected backfill soils are utilized and the angle of the line tangent to the bowed wall is equal to the largest natural soil slip angle of the at least two preselected backfill soils.

7. The corrugated pipe of claim 4, wherein when at least two preselected backfill soils are utilized the angle of the line tangent to the bowed wall is equal to the largest natural soil slip angle of the at least two preselected backfill soils, and the angle of a line drawn from the peak of the bowed wall to an exterior corner of the radially outer end of at least one of the annular straight walls is equal to the smallest natural soil slip angle of the at least two preselected backfill soils.

8. The corrugated pipe of claim 1, wherein the natural soil slip angle of the soil is between about 28° and about 37.5°.

9. The corrugated pipe of claim 1, wherein each inner portion of the radially inner ends of the annular straight walls of a corrugation structure flare toward the interior of the corrugation structure in arcuate curves to join with the radially outer edge of the cylindrical wall.

10. The corrugated pipe of claim 9, wherein the radii of the arcuate curves is about equal to or greater than one half the thickness of the cylindrical wall.

11. The corrugated pipe of claim 1, wherein the angle between the annular straight walls and the longitudinal axis is set so that the corrugation structure will withstand a vertical force expected to be applied to the corrugation structure.

12. The corrugated pipe of claim 1, wherein the thickness of the annular U-shaped wall and the cylindrical wall is uniform.

13. The corrugated pipe of claim 1, wherein the thickness of the annular U-shaped wall and the cylindrical wall is minimized.

14. The corrugated pipe of claim 1, wherein the thickness of the annular U-shaped wail and the cylindrical wall of each corrugation structure is based on a relationship between a maximum burial depth of the pipe, a resistance to hydraulic compression of the pipe, a 30% yield test criteria, and AASHTO testing requirements.

15. The corrugated pipe of claim 1, wherein the corrugated pipe is stable under hydraulic and compressive soil loads.

16. The corrugated pipe of claim 15, wherein the corrugated pipe is configured to withstand hydraulic loading at 10.8 psi.

17. The corrugated pipe of claim 1, wherein the corrugated pipe is formed from a material selected from the group consisting of polyethylene and plastic.

18. The corrugated pipe of claim 1, wherein the corrugated pipe is formed from high density polyethylene.