Molded Pulp Void Forming Device for Concrete
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Solution Overview
Problem
Existing void forming devices in concrete structures are prone to premature deterioration due to moisture and unable to withstand the weight of wet concrete, leading to structural failure and inefficiencies in construction processes.
Innovation Solution
The development of a void forming device made from molded pulp, which includes wax-coated corrugated cardboard and features channels that resist water penetration, allowing the device to support concrete during curing and accommodate soil expansion, while being biodegradable and recyclable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional corrugated cardboard support structures are used to create voids in concrete, then the forms are easy to manufacture and assemble, but they collapse under the weight of wet concrete due to moisture susceptibility
Solution Approach 1:
The patent applies composite materials by combining molded pulp with wax coatings to create a void form that maintains structural strength while resisting moisture. The molded pulp provides the base structure, and the wax coating adds water resistance, creating a composite material that overcomes the limitations of traditional corrugated cardboard while remaining manufacturable through molding processes.
2Reliability
If corrugated cardboard forms are used to create voids, then the device complexity is low and assembly is simple, but the forms deteriorate prematurely due to moisture exposure
Solution Approach 1:
The patent applies parameter changes by modifying the physical and chemical properties of the void form material. The molded pulp undergoes changes in moisture resistance through wax coating, and the material composition is adjusted to balance structural integrity with water resistance. These parameter changes enable the form to maintain reliability throughout the concrete curing process without premature deterioration.
3Strength
If void forms are designed to resist moisture, then structural integrity is maintained under wet concrete, but the ability of soil to fill pockets over time is restricted
Solution Approach 1:
The patent applies dynamics by designing a void form that transitions from a moisture-resistant structural state during concrete pouring to a gradually decomposable state over time. The molded pulp structure maintains its form and strength initially to support wet concrete, then progressively breaks down to allow soil infiltration, creating a dynamic material behavior that adapts to different stages of the construction and settlement process.
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 molded pulp void forming device provides enhanced structural strength, resistance to moisture, and efficient soil accommodation, reducing construction delays and costs by maintaining structural integrity under wet concrete loads and allowing for easier transportation and assembly.
Implementation Method 1
wax-coated corrugated cardboard that resists water penetration
Data Source
AI summary
This disclosure describes devices and methods for forming voids in or adjacent concrete structures. In some embodiments, a device may include a structure. The structure may be substantially planar. The structure may include a plurality of channels extending therefrom. In some embodiments, the channels are closed at a first end distal from the structure. In some embodiments, the channels are open at a second end proximal to the structure. In some embodiments, the device may be formed from a molded pulp. The molded pulp may be configured to inhibit penetration of water. In some embodiments, the device may be configured to substantially support poured concrete during at least a portion of a curing process of the poured concrete.