Waterproof Void Form for Expansive Soil

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Solution Overview

Problem

Conventional paper-based void forms used in construction are prone to moisture absorption, leading to reduced strength, increased costs due to excess material usage, and unpredictable performance, which can compromise the structural integrity of concrete foundations built on expansive soils.

Innovation Solution

A waterproof construction unit comprising an outer host shell and an impervious internal cellular structure, where the shell provides initial structural support and gradually deteriorates, while the cellular structure maintains rigidity and flexibility to accommodate soil movement, allowing for precise moisture management and reduced material usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If paper-based void forms are used to create void space, then the form can be easily manufactured and installed, but the form absorbs moisture and deteriorates quickly, compromising structural integrity

Engineering Contradiction:

Improveease of manufactureVSAvoidstructural integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent combines paperboard material with a water-soluble polymer coating to create a composite void form that maintains the ease of manufacture of paper products while adding moisture resistance through the polymer layer, thereby preserving structural integrity in humid conditions

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the physical-chemical parameters of the paperboard by applying a water-soluble polymer coating, which changes the material's moisture absorption characteristics and deterioration rate, allowing the form to maintain strength longer in wet environments

Inventive Principle:

Principle #35Parameter changes

2Strength

If excess paper material is used to compensate for moisture susceptibility, then the form strength is maximized, but material cost and waste increase

Engineering Contradiction:

Improveform strengthVSAvoidmaterial waste

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

The patent uses a polymer-coated paperboard composite that provides enhanced moisture resistance, allowing the use of optimally sized forms without excessive material while maintaining required strength levels throughout the concrete curing process

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent employs a disposable polymer-coated paperboard form that is designed to deteriorate controllably after serving its purpose, eliminating the need for expensive reusable forms while avoiding material waste through precise sizing and optimized deterioration timing

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Object-affected harmful factors

If waterproof covering is used to protect paper void forms from moisture, then moisture resistance is improved, but ventilation is limited and humidity becomes trapped

Engineering Contradiction:

Improvemoisture resistanceVSAvoidventilation

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The patent uses a water-soluble polymer coating that changes its permeability parameters over time - initially providing moisture resistance during concrete placement, then gradually dissolving to allow ventilation and humidity release during the curing period

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The polymer coating creates a temporary protective environment around the paperboard form, shielding it from harmful moisture during critical periods while maintaining controlled breathability through its gradual dissolution characteristics

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

4Productivity

If paper void forms are used in saturated soil conditions, then the form can be installed quickly, but the form absorbs standing water and deteriorates prematurely

Engineering Contradiction:

Improveinstallation speedVSAvoidform durability

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The patent combines paperboard with a water-soluble polymer coating to create a composite form that resists saturated soil conditions and standing water during installation and concrete placement, while maintaining predictable deterioration timing for long-term durability

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The polymer coating provides beforehand protection against moisture absorption and premature deterioration, cushioning the paperboard form against the harmful effects of saturated soil conditions during the critical installation and curing period

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS9797147B2Water proof construction unit

Publication Date: 2017.10.24 VOIDFORM PRODUCTS LLC

AI summary

The present application includes a void form unit for creating a void space between concrete structures and expansive soil. The unit includes a cellular structure surrounded by a paper based shell. The cellular structure is impervious to moisture. Together the cellular structure and the shell make a singular rigid member. The rigid member is configured to temporarily support concrete and gradually increase in flexure so as to flex with the movement of the expansive soil. The shell is configured to weaken over time from the regulated absorption of moisture. The flexure of the cellular structure configured to increase with the deterioration of the shell.