Permeable Polymer Filament Shell for Masonry Debris Collection

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Solution Overview

Problem

Masonry cavity walls face issues with moisture accumulation and obstruction of weep vent passages due to mortar and debris, leading to potential damage and costly repairs, as existing solutions fail to effectively prevent blockage and ensure drainage.

Innovation Solution

A water-permeable mortar and debris collection device with a contoured shell of polymer filaments is inserted into the cavity, featuring extensions with shelves and ridges to collect and suspend debris above weep vent passages, allowing moisture to pass through while preventing blockage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If weep vent passages are provided to drain moisture from the cavity, then moisture drainage is improved, but the passages become obstructed by mortar and debris

Engineering Contradiction:

Improvemoisture drainageVSAvoidblockage by mortar and debris

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A water-permeable collector device is inserted into the cavity to act as an intermediary between the mortar/debris and the weep vent passages. The device collects and suspends mortar droppings and sizable debris in its interior volume, preventing them from reaching and blocking the weep vents while allowing moisture to pass through its water-permeable walls

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The collector device segments the cavity space by creating a distinct collection zone separated from the weep vent openings. The device divides the harmful mixture of mortar and debris from the drainage pathway, allowing moisture to continue flowing to the vents while trapping solid particles in the collector's interior

Inventive Principle:

Principle #1Segmentation

2Reliability

If the cavity is left open for drainage, then moisture can escape, but mortar and debris accumulate and block drainage

Engineering Contradiction:

Improveair circulation and drainageVSAvoidaccumulation of mortar and debris

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The water-permeable collector device serves as a mediator that allows air circulation and moisture drainage to continue while intercepting and holding mortar and debris. The device's water-permeable walls permit airflow and moisture passage while its interior volume captures harmful particles

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The device converts the harmful accumulation of mortar and debris into a beneficial suspension within its controlled interior volume. By trapping debris in the collector rather than allowing it to block weep vents, the harmful factor is transformed into a contained, manageable state that preserves drainage functionality

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If a collector device is inserted to prevent blockage, then drainage is maintained, but the device structure adds complexity

Engineering Contradiction:

Improvedrainage maintenanceVSAvoidstructure of collector device

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The collector device utilizes a water-permeable shell or film structure that provides the necessary containment function with minimal material and structural complexity. The thin-film water-permeable walls maintain drainage functionality while containing mortar and debris, avoiding the need for complex rigid structures

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The device employs water-permeable porous material for its walls, allowing moisture and air to pass through while blocking mortar and debris. This porous structure achieves the dual function of filtration and permeability with a simple, uniform material rather than complex multi-component structures

Inventive Principle:

Principle #31Porous materials

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 device effectively collects and suspends mortar and debris, ensuring unobstructed drainage and air circulation, thereby preventing damage and maintaining the integrity of masonry cavity walls.

Implementation Method 1

a water permeable body that includes a contoured shell formed of an open space array of polymer filaments

Methodology Applied

Scientific EffectPermeation: Permeation

Data Source

PatentUS8621800B2Mortar and debris collection system for masonry cavity walls

Publication Date: 2014.01.07 KEENE BUILDING PRODS

AI summary

A mortar and debris collection device for use in a masonry wall assembly includes a water permeable body made of an open-space defining array of polymer filaments that twist and turn between filament intersections where adjacent filaments are bonded to each other. The water permeable body comprises a shell having a hollow interior and includes an elongated base and extensions upwardly projecting from the base.