Extendable Concrete Deck Sleeve With Snap-Fit Height Adjustment
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Solution Overview
Problem
Existing extendable tubular sleeves for poured concrete decks are cumbersome to assemble, prone to vertical misalignment, and can damage flexible diaphragms during use, with the current method of adjusting length being time-consuming and inaccurate.
Innovation Solution
An improved cap and assembly system featuring snap-fit connections, over-molded diaphragms, and adjustable caps with positioning tabs to facilitate easier assembly and length adjustment, ensuring secure and aligned connections without damaging the diaphragm, and supporting floor drain fittings independently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If threaded fasteners are used to connect the base parts, then the connection is secure, but the assembly becomes cumbersome and time-consuming
Solution Approach 1:
The base is divided into two separate parts that can be quickly connected using a snap-fit mechanism, eliminating the need for threaded fasteners. The segmentation allows for rapid assembly while maintaining structural integrity through the interlocking design of the base parts.
Solution Approach 2:
The threaded fastener system is replaced with a snap-fit mechanical connection. This substitution eliminates the time-consuming threading operation while providing sufficient connection strength through the elastic deformation and locking feature of the snap-fit mechanism.
2Strength
If the flexible diaphragm is clamped between the base and threaded sleeve, then the diaphragm is secured, but the threading rotation damages and distorts the diaphragm
Solution Approach 1:
The threaded sleeve connection is replaced with a snap-fit connected cap. This substitution eliminates the rotational threading action that damages the diaphragm while maintaining secure clamping through the elastic snap-fit mechanism that applies uniform pressure without distortion.
Solution Approach 2:
The cap acts as an intermediary component that secures the diaphragm without direct threading contact. The snap-fit connection in the cap transfers the securing force to the diaphragm in a controlled manner, preventing the distortion that would occur with direct threaded engagement.
3Manufacturing precision
If the sleeve is cut to length, then the precise fit is achieved, but the process is time-consuming and cumbersome
Solution Approach 1:
The sleeve length is made adjustable through the snap-fit connected cap that can be positioned at different locations along the sleeve. This dynamic adjustment eliminates the need for cutting, allowing quick length changes by simply repositioning the cap while maintaining precise fit through the snap-fit engagement with the sleeve ridges.
Solution Approach 2:
The sleeve system is segmented into the main sleeve and the adjustable cap component. This segmentation allows the cap to be independently positioned and adjusted along the sleeve length, providing precise length adjustment without requiring cutting or modification of the main sleeve structure.
4Ease of manufacture
If the vertically-split base is used, then the assembly can be constructed, but vertical misalignment of the split parts occurs
Solution Approach 1:
The two vertically-split base parts are merged into a single monolithic base structure. This merging eliminates the interface between split parts, preventing vertical misalignment while maintaining ease of construction through the simple single-piece design that requires no assembly of base components.
Data Source
AI summary
An improved cap and assembly is provided for a poured concrete deck. The improved assembly has a diaphragm seal over-molded to a top plate having a depending sidewall that is snap-fit to a base containing a fire ring. A tubular sleeve is connected to the over-molded top plate by snap fit connections to the sidewall and by threaded fasteners passing through sockets in the sleeve, sidewall and base. The over-molded diaphragm has a funnel shape. A first sleeve cap has depending positioning tabs that may be broken off to adjust the cap height relative to the sleeve, with an inwardly extending latching surface engaging the sleeve when the tabs are removed. A second cap has inwardly extending tabs that fit into channels on the sleeve fit between ridges on the sleeve when rotated to adjustably position the second cap on the sleeve.