Disposable Foam Plug for Concrete Enclosure Sealing
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Solution Overview
Problem
During the installation of utility enclosures or penetrations in concrete forms, concrete often flows between the form and the tape, creating a skim layer and entering the enclosure through gaps, leading to incomplete sealing and curing issues.
Innovation Solution
A plug design with a sidewall and lid configuration that fits into the open end of the enclosure, featuring a flange and projection for sealing, and a tool engagement section for easy removal, along with environmental sealing materials and clips for secure installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tape is used to close the bottom end of the enclosure, then the enclosure can be sealed, but concrete flows through the tape and creates a skim layer, resulting in incomplete sealing
Solution Approach 1:
The patent uses disposable plugs made of foam or other absorbent materials that are inserted into the enclosure openings to seal them during concrete pouring. These plugs are designed to be consumed or destroyed during the process, as they are later removed after the concrete cures. The plugs provide reliable sealing during the critical pouring phase but are discarded afterward, eliminating the need for durable permanent seals at this stage.
Solution Approach 2:
The plugs are installed in advance of the concrete pouring operation to seal the enclosure openings and prevent concrete ingress. This preliminary sealing action ensures that when concrete is poured, it cannot flow through the openings or create skim layers. The plugs are positioned and secured before the harmful concrete flow occurs, preventing the problem rather than correcting it afterward.
2Ease of manufacture
If tape is used to seal the enclosure, then the opening is closed, but the tape does not form a sufficient seal and concrete enters through seams or gaps
Solution Approach 1:
The plugs are constructed from composite materials, particularly foam materials that combine expandability, sealability, and structural integrity. The foam material can expand to fill gaps and conform to the enclosure opening geometry, creating a reliable seal that tape cannot achieve. This composite approach combines the simplicity of a single-piece plug with the sealing effectiveness of expandable material.
Solution Approach 2:
The plug material undergoes parameter changes during installation and service. The foam material expands after insertion, changing its volume and density to create a tight seal against the enclosure opening. This parameter change from compressed to expanded state ensures that the plug forms a sufficient seal that prevents concrete ingress through seams or gaps, while maintaining ease of installation in the compressed state.
3Reliability
If the enclosure is sealed with tape during concrete pouring, then the opening is closed, but concrete creates a skim layer that must be removed before accessing the enclosure
Solution Approach 1:
The plugs are designed as disposable temporary seals that serve their purpose during concrete pouring and are then removed. They are not intended to remain in place permanently, unlike traditional tape that creates difficult-to-remove skim layers. The plugs can be easily pulled out after the concrete cures, providing full access to the enclosure without requiring skim layer removal operations.
Solution Approach 2:
The plugs are designed to be easily extracted or removed from the enclosure openings after the concrete has cured. This extraction is straightforward compared to removing tape and skim layers, as the plugs simply pull out or can be cut away with minimal effort. The design allows for complete removal of the sealing element without leaving behind concrete deposits or requiring additional removal steps.
Data Source
AI summary
Plugs and covers for a utility enclosure or penetration prevent the ingress of concrete. One plug includes a sidewall configured to be received in an open end of the utility enclosure or penetration, the sidewall defines a periphery. The plug also includes a lid extending over one end of the sidewall, the lid having a body extending over an inner peripheral area defined by the sidewall, and a flange extending outwardly from the body. A cover fits over a top of the enclosure and seals to the enclosure or a blank covering the enclosure. Connector plugs prevent concrete from entering connector openings and an environmental sealing material is applied to an outside of the enclosure. A clip for securing the utility enclosure to a form is also disclosed.