Polymeric Upper Beam Slab Bolster with Snap-Fit Modular Design

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Solution Overview

Problem

Conventional bolsters used in construction for supporting post-tension cables, rebars, or mesh face issues with corrosion, high manufacturing costs, and inability to withstand forces effectively, especially when used as upper beam bolsters on mesh or slab-on-grade surfaces, where they may sink into soil or require labor-intensive assembly.

Innovation Solution

An upper beam slab bolster integrally formed of polymeric material through injection molding, featuring a beam with converging leg members and a snap-fit connection system for easy assembly and extension, providing a wide base for stability and resistance to corrosion, and allowing for nesting and efficient transportation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal bolsters are used for supporting rebar and mesh, then structural strength is improved, but corrosion resistance deteriorates and manufacturing cost increases

Engineering Contradiction:

Improvestructural strengthVSAvoidcorrosion resistance

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The invention uses polymeric material (composite material) to replace traditional metal materials, achieving both structural strength and corrosion resistance. The polymer bolster maintains the necessary load-bearing capacity while being inherently resistant to corrosion, eliminating the need for protective coatings or stainless steel alternatives.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The polymer bolster is designed as a cost-effective, single-use component that eliminates the need for expensive metal materials and anti-rust coatings. While disposable, it provides sufficient strength for its intended construction application and simplifies maintenance by eliminating corrosion protection requirements.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Ease of manufacture

If plastic bolsters are used to reduce cost and corrosion, then manufacturing cost is improved, but load-bearing capacity deteriorates

Engineering Contradiction:

Improvemanufacturing costVSAvoidload-bearing capacity

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The invention employs curved or angled leg members that converge toward the beam, creating a geometric structure that efficiently distributes and transfers loads. This curved configuration, combined with the polymeric material, provides the necessary structural strength while maintaining cost-effective manufacturing through integral forming processes.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The use of engineered polymeric material provides both the economic advantage of plastic manufacturing and the structural performance previously only achievable with metal. The material properties are selected to ensure adequate load-bearing capacity while maintaining cost-effectiveness.

Inventive Principle:

Principle #40Composite materials

3Strength

If conventional metal bolsters with narrow feet are used, then structural integrity is improved, but stability on soft surfaces deteriorates

Engineering Contradiction:

Improvestructural integrityVSAvoidstability on soft surfaces

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The invention transitions from narrow, point-like feet to wide, distributed base structures. The leg members spread out to provide a larger contact area with the underlying surface, distributing the load over a wider area to prevent sinking into soft surfaces like soil or sand, while maintaining structural integrity through the polymeric material and geometric configuration.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Manufacturing precision

If bolsters are made in preset lengths with welded connections, then manufacturing precision is improved, but ease of operation deteriorates

Engineering Contradiction:

Improvepreset length accuracyVSAvoidease of assembly

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The invention divides the bolster into modular segments that can be easily connected through snap-fit mechanisms. This segmentation allows for simple field assembly and extension while maintaining manufacturing precision through integral forming of each module. The snap-fit connections enable quick assembly without requiring welding or specialized tools.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention replaces complex welding operations with simple snap-fit mechanical connections. This substitution maintains the precision of preset lengths through controlled manufacturing of each module while dramatically simplifying the assembly process, allowing workers to connect bolsters quickly without specialized equipment or skills.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS7870703B1Upper beam slab bolster for use in construction

Publication Date: 2011.01.18 SORKIN FELIX L

AI summary

A bolster for use in construction has a beam, a pair of spaced apart foot members, a first plurality of leg members on one side of the beam, and a second plurality of leg members on an opposite side of the beam. The first plurality of leg members are connected at one end to the beam and at the opposite end to one of the pair of spaced apart foot members. The second plurality of leg members are connected at one end to the beam and at the opposite end to the other of the pair of spaced apart foot members. The beam, pair of spaced apart foot members and first and second pluralities of leg members are integrally formed together of a polymeric material. Multiple lengths of bolster may be joined together in a snap-fit engagement.