Dual-Stage Plug Assembly for Basement Wall Sealing
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Solution Overview
Problem
Existing methods for sealing holes in structures, such as basement walls, are inadequate as they fail to completely prevent water flow, are messy, time-consuming, and use materials that degrade quickly, posing health risks.
Innovation Solution
A dual-stage plug assembly comprising an insertion member, a coupling member, and an expansion member made from materials with varying hardness, where the expansion member expands upon contact with water to provide a comprehensive seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If epoxy or flowable material is placed into the hole to seal it, then the hole is sealed, but the process is time-consuming, messy, and the materials degrade quickly
Solution Approach 1:
The patent changes the physical state of the sealing material from liquid (epoxy) to solid (expandable granules). The granules are inserted in dry form and then expand upon contact with water, transforming from a compact state to an expanded sealing mass that fills the hole effectively.
Solution Approach 2:
The expandable granules are self-activating sealing agents that automatically expand when they contact water, eliminating the need for manual application processes, mixing, or curing time required by epoxy. The material performs its own sealing function through automatic expansion.
2Reliability
If epoxy or flowable material is placed into the hole to seal it, then the hole is sealed, but the process is messy and provides an undesirable appearance
Solution Approach 1:
The material transitions from solid granules to expanded solid form in-situ within the hole, avoiding the messiness of liquid application. The expansion occurs contained within the hole, and the final sealed appearance is clean and neat.
Solution Approach 2:
The messy application process of epoxy (mixing, pouring, smoothing) is completely removed from the procedure. Only simple insertion of dry granules is required, extracting all the messy steps from the sealing process.
3Reliability
If epoxy or similar materials are placed into the hole, then the hole is sealed, but the materials are poisonous and degrade quickly, requiring removal and replacement
Solution Approach 1:
The patent uses composite expandable granules that combine multiple properties: water-absorbing capability, structural integrity upon expansion, and chemical inertness. This composite structure provides both effective sealing and long-term durability without degradation or toxicity.
Solution Approach 2:
The expandable granules are designed as a single-use, disposable sealing solution that provides permanent sealing without degradation. Unlike epoxy that degrades and requires replacement, these granules maintain their sealing function indefinitely, eliminating the need for removal and replacement.
4Ease of operation
If an item is placed into the hole to seal it, then partial sealing is achieved, but water and liquids continue to flow through the unsealed portion
Solution Approach 1:
The material undergoes a volume expansion parameter change upon water contact, transforming from compact granules to an expanded mass that completely fills the hole. This expansion ensures complete sealing of all pathways, preventing any water flow through unsealed portions.
Solution Approach 2:
The sealing material is dynamic rather than static - it actively expands in response to water contact, adapting its volume and shape to completely fill the hole and seal all pathways. This dynamic response ensures complete sealing rather than static partial sealing.
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 assembly effectively prevents water flow through holes by initially slowing it with the insertion member and then fully sealing with the expanding material, offering a durable and safe solution.
Implementation Method 1
an expansion member which expands upon contact with water and which surrounds the body of the coupling member
Data Source
AI summary
A dual stage plug assembly 10 which provides a first sealing stage which is cooperatively provided by the insertion members 12, 14 (including the unexpanded portion 24) and a second sealing stage which is provided by selectively expandable member 24. The plug assembly 10 is selectively inserted into a hole, such as hole 80, which is formed in a tangible entity, such as basement wall 82, and the members 12 and 14 cooperates with member 24 to seal the hole 80, thereby preventing water and/or other liquid from entering and passing through the hole 80.