Tubular Sleeve Cap Assembly for Precise Concrete Drain Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing extendable sleeves for poured concrete structures are cumbersome to assemble, prone to misalignment, and can damage flexible diaphragms, while adjusting their length is time-consuming and inaccurate, and they do not effectively support heavy floor drain fittings during concrete pouring.
Innovation Solution
An improved cap and assembly system featuring a snap-fit connection with an over-molded diaphragm seal, threaded fasteners, and adjustable caps that allow for easy length adjustment and secure support of floor drain fittings without damaging the diaphragm, using a tubular sleeve with radially extending ridges and channels for precise alignment and adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a vertically-split base with threaded fasteners is used to connect the sleeve to the metal frame, then the connection can be secured, but the assembly becomes cumbersome and allows vertical misalignment
Solution Approach 1:
The base is divided into two separate halves that wrap around the pipe, allowing easy assembly by simply placing the halves together without threaded fasteners. The segmented design eliminates complex assembly steps while maintaining connection integrity through the wrap-around configuration.
Solution Approach 2:
A positioning element is introduced as an intermediary component between the base halves to prevent vertical misalignment. This mediator ensures proper alignment during assembly without requiring threaded fasteners, resolving both the alignment and assembly ease issues simultaneously.
2Reliability
If a flexible diaphragm is clamped between the base top and a threaded sleeve, then the diaphragm provides sealing, but the threading rotation damages and distorts the diaphragm
Solution Approach 1:
The threaded mechanical connection system is replaced with a snap-fit engagement system. The cap features a snap-fit portion that engages with a corresponding feature on the base, eliminating rotational threading motion that damages the diaphragm while maintaining secure connection and sealing integrity.
Solution Approach 2:
The snap-fit portion acts as an intermediary mechanism that transfers the locking function from threaded rotation to elastic engagement. This mediator protects the diaphragm from direct contact with damaging rotational forces while maintaining the sealing function.
3Manufacturing precision
If the inner tubular sleeve is cut to length, then the sleeve fits the required dimension, but the process is time-consuming and inaccurate
Solution Approach 1:
The sleeve length is made adjustable rather than fixed. The sleeve can be extended or reduced in length as needed, eliminating the need for cutting operations. This dynamic length adjustment provides both time efficiency and precision without requiring manual cutting operations.
Solution Approach 2:
The length parameter of the sleeve is changed from a fixed value to an adjustable range. By allowing the sleeve length to vary within a specified range, the system eliminates the need for precise cutting operations while maintaining the required dimensional accuracy for different installation scenarios.
4Measurement precision
If floor drain fittings are supported independently of the extendable sleeves, then the fittings can be precisely positioned, but the support structure becomes complex and requires additional components
Solution Approach 1:
The extendable sleeve is designed to perform multiple functions: it provides the concrete passage formation and simultaneously serves as the support structure for floor drain fittings. This multi-functional design eliminates the need for separate support components while maintaining precise positioning capability through the sleeve's inherent structural features.
Solution Approach 2:
The support function for floor drain fittings is merged with the extendable sleeve structure itself. Rather than using independent support components, the sleeve integrates both functions, simplifying the overall system while maintaining the precision required for proper fitting installation.
Data Source
AI summary
A cap for a tubular sleeve having a cylindrical wall extending along a longitudinal axis for forming a passage through a concrete structure. The sleeve has radially extending ridges separated into segments with a channel parallel to the longitudinal axis. The channel has a circumferential width W. The ridges spaced apart a distance Z along the longitudinal axis. The sleeve having an inner diameter D. The cap has a cap element and a positioning tab. The cap element has a circular outer periphery with a flat top surface and a flange having a bottom end, and the tab extends inwardly from the bottom end and has a bottom surface that is orthogonal to the longitudinal axis. The tab has an inner surface that is inclined at an acute angle to the bottom surface. The tab has a width smaller than W and an axial length smaller than Z.