Interlocking Spacer System for Conduit Alignment
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Solution Overview
Problem
During concrete pouring operations, conduits and pipes often sag or displace due to lack of proper support, leading to poor alignment and configuration issues, resulting in plumbing and electrical problems.
Innovation Solution
An interlocking and latching alignment and support apparatus that acts as a rigid structure, using integral latches to prevent vertical movement of conduit spacers, allowing for easy assembly and disassembly, and can be scaled and made from various materials like plastics, composites, and metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rebar and tape are used to support conduit sections, then the conduit can be temporarily supported during construction, but the conduit will sag and displace during concrete pouring because the support structure is not rigid enough
Solution Approach 1:
The support system is divided into modular spacer sections that can be assembled in segments along the conduit run. Each spacer acts as an independent support unit that can be quickly installed and provides localized rigid support to prevent sagging during concrete pouring.
Solution Approach 2:
The spacer integrates multiple functions into a single component: it provides rigid structural support, maintains conduit spacing and alignment, and includes built-in latching mechanisms for secure assembly. This merging of support, alignment, and fastening functions into one rigid structure eliminates the inadequacy of separate rebar and tape components.
2Reliability
If conduit spacers are made as a rigid interlocking structure with latches, then the spacers prevent vertical movement and maintain alignment during concrete pouring, but the assembly and disassembly process becomes more complex
Solution Approach 1:
The spacer is designed as a modular unit with standardized interlocking features that simplify assembly. Each spacer section is a self-contained module that connects to adjacent sections through repetitive, simple latching actions rather than complex fastening procedures.
Solution Approach 2:
The latching mechanism is designed to be self-latching through simple manual engagement. The interlocking features automatically secure when pieces are joined, and the release mechanism allows easy disassembly without requiring specialized tools or complex procedures, enabling workers to quickly assemble and disassemble the support system.
3Ease of manufacture
If traditional rebar support is used that requires removal before concrete pouring, then footers can be dug, but the conduit configuration becomes crooked and misaligned during the pouring process
Solution Approach 1:
The rigid spacers are installed on the conduit before the concrete pouring operation begins. This preliminary installation of stable support structures ensures that the conduit maintains its precise alignment and configuration throughout the pouring process, preventing the sagging and misalignment that occurs when temporary rebar support is removed.
Solution Approach 2:
The spacer system provides preemptive structural reinforcement to the conduit assembly before the concrete pour. By establishing a rigid support framework in advance, the system cushions the conduit against the forces and movements that would otherwise cause misalignment during pouring, ensuring precision is maintained throughout the construction process.
Data Source
AI summary
An interconnecting alignment and support system for supporting and maintaining alignment of at least one conduit or pipe is disclosed. The system may be used, for example, during a concrete pour operation or other construction operation. The system comprises a base spacer and, optionally, one or more of an intermediate spacer and/or another base spacer. The base spacer is constructed to be capable of interlocking with another spacer on each side and the top. The intermediate spacer is constructed to be capable of interlocking with another spacer on each side and both the top and bottom. The interlocks on the spacers may be releasably latched when fully interlocked. By interlocking the spacers, a matrix structure for aligning and supporting conduit or pipe may be created. The base spacer is attachable to a surface, so that the alignment and support system may be fixed in place.