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, requiring manual chipping of concrete and the use of costly hollow boxes.
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 is later removed to leave a void after the concrete hardens, allowing for external pipe connections and pressure testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hollow boxes are used to create void spaces around pipes, then the void space is created, but the device becomes expensive and cumbersome to install
Solution Approach 1:
The invention divides the void-creating device into two separate components: a cap that fits over the pipe end and a removable plug that fills the void space. This segmentation allows each component to be simple in structure while working together to create the necessary void space, eliminating the need for complex hollow boxes.
Solution Approach 2:
The invention extracts the essential function of creating void space from the complex hollow box structure. By using a simple cap and plug combination, the patent removes unnecessary complexity while retaining the core functionality of creating and maintaining void spaces around pipes during concrete pouring.
2Adaptability or versatility
If manual chipping is used to create space for pipe connections, then the connection space is created, but labor time and cost increase
Solution Approach 1:
The invention performs preliminary action by creating the void space around the pipe before the concrete is poured and hardened. The cap and plug are installed in advance, allowing connections to be made easily after concrete hardening without requiring manual chipping, thus saving significant labor time.
Solution Approach 2:
The cap and plug assembly serves as an intermediary device that facilitates future connections. By maintaining a clean void space around the pipe, the invention enables easy attachment of fittings and connections without requiring destructive manual chipping of hardened concrete.
3Reliability
If the plug has a smaller inner diameter than the tube, then concrete is kept out of the pipe, but removal difficulty increases
Solution Approach 1:
The invention changes the physical parameters of the plug by making it slightly compressible, allowing it to be inserted with an interference fit that excludes concrete effectively. The same compressibility parameter enables easy removal by applying slight compression force, resolving the contradiction between secure fit and ease of removal.
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 without the need for expensive boxes, simplifying installation and reducing manual labor, while ensuring a clean and strong separation from the concrete surface, facilitating external connections and pressure testing.
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
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.