Riser Cap and Foam Plug Assembly for Concrete Void Formation
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Solution Overview
Problem
Existing methods for creating void spaces around pipes or risers in concrete surfaces are cumbersome, expensive, and difficult to use, particularly when manual chipping of concrete is required for pipe connections or fittings.
Innovation Solution
An assembly comprising a cap with a cylindrical skirt and an annular foam plug is used to create an interference fit around the pipe, preventing concrete from filling the void space, which can be easily removed after concrete hardening to leave a void, and the cap can be glued for pressure testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If hollow boxes are used to create a cavity around the tops of the pipes, then a void space is created, but the boxes are expensive to create, cumbersome to align and install, and difficult to use
Solution Approach 1:
The invention divides the void-creating device into two separate components: a cap that fits over the pipe and a skirt that extends into the concrete. This segmentation allows each component to be simple in design while working together to create the required void space, eliminating the need for complex hollow boxes
Solution Approach 2:
The invention extracts the essential function of creating a void space from the complex hollow box structure. By using a simple cap and skirt assembly that merely needs to occupy the space around the pipe, the void-creating function is achieved without the cumbersome features of previous box designs
2Adaptability or versatility
If manual chipping of concrete is used to create space for pipe connections, then connections can be made, but the process is time-consuming and labor-intensive
Solution Approach 1:
The cap and skirt assembly is installed on the pipe before the concrete is poured. This preliminary action creates the void space in advance, so that when the concrete hardens, the connection space is already prepared and no manual chipping is required
Solution Approach 2:
The skirt acts as an intermediary between the pipe and the concrete. It extends into the concrete to create a controlled void space that facilitates future pipe connections without requiring destructive manual chipping of the hardened concrete
3Reliability
If the plug has an undeformed inner diameter smaller than the outer diameter of the tube, then an interference fit is created to keep concrete out, but the plug must be compressed to install
Solution Approach 1:
The plug is made of foam material that can change its physical parameters (compressibility) during installation. When installed, it is compressed to fit tightly around the pipe, creating a reliable seal. Once the concrete hardens, the plug can be easily removed by pulling, as the foam retains its elasticity
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
This method efficiently creates a void space around pipes or risers in concrete without the need for expensive or cumbersome devices, allowing for easy removal and pressure testing, thereby simplifying the process of embedding pipes in concrete.
Implementation Method 1
The plug has an undeformed inner diameter that is smaller than an outer diameter of the tube to create an interference fit around the tube and keep concrete out when the plug fits over the distal end of the tube
Data Source
AI summary
An assembly creates annular voids in concrete around the distal end of cylindrical tubes. A cap has a flat top and a cylindrical, depending skirt. An annular, foam plug extends between the inside of the skirt and the outer diameter of the tube. The plug has an undeformed inner diameter smaller than an outer diameter of the tube to create an interference fit around the tube and keep concrete out when the cap is on the end of the tube. The plug has a radial thickness of 0.3 to 1 inch, and has an axial length of 1 to 3 inches, with a bottom of the plug located at a bottom of the skirt. The cap is glued to the end of the tube for pressure testing. After the tube is entrained in concrete, the cap and plug are removed to leave a void in the concrete surface.