Aluminium Formwork Panel Frame with Sliding Connectors
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Solution Overview
Problem
Traditional timber formwork for constructing elevated concrete slabs is labor-intensive, slow to assemble and disassemble, and results in dimensional variations and curved or non-parallel sides, leading to inefficiencies and high labor costs.
Innovation Solution
A disassemblable formwork panel frame with longitudinal side and end beams, and connectors that slide into cavities for secure assembly and disassembly, ensuring parallel and straight edges, using aluminium extrusions for structural strength and consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If full length welds are used to connect frame members, then the frame achieves strong structural connection, but the construction time increases and dimensional variations occur
Solution Approach 1:
The frame members are segmented with standardized connection zones at regular intervals, allowing assembly without continuous welding. The connection zones are divided into discrete locations where connectors are positioned, enabling modular assembly that reduces construction time while maintaining structural strength through distributed connection points.
Solution Approach 2:
Connection zones are pre-formed during extrusion with precise geometry and positioning. This preliminary action ensures that when frame members are assembled, the connectors fit into pre-configured receptacles without requiring time-consuming field welding or adjustment, thereby reducing construction time while ensuring consistent connection strength.
2Strength
If full length welds are used to connect frame members, then the frame achieves strong structural connection, but dimensional variations and curvature occur between welding points
Solution Approach 1:
The frame is divided into segments with standardized connection zones at regular intervals. This segmentation eliminates the need for continuous welding, thereby preventing the accumulation of dimensional variations and curvature that occur during long welding operations. Each segment can be manufactured with high precision and assembled consistently.
Solution Approach 2:
The manufacturing process transitions from welding to mechanical connection through extruded connectors. This parameter change in the joining method eliminates thermal distortion and dimensional variations associated with welding, while maintaining strong structural connections through precisely engineered mechanical interfaces.
3Ease of manufacture
If traditional timber formwork is used, then the structure can be assembled with simple materials, but the assembly and disassembly process is labor intensive and slow
Solution Approach 1:
The formwork system transitions from traditional timber to extruded aluminium frame members with integrated connectors. This parameter change in material and construction method enables rapid assembly through simple connector insertion rather than labor-intensive timber joining, significantly improving productivity while maintaining ease of manufacture through standardized extrusion processes.
Solution Approach 2:
The formwork is divided into modular panels with standardized frame members and connectors. This segmentation allows quick assembly by simply connecting pre-fabricated modules together, eliminating the need for complex on-site timber construction and dramatically increasing assembly speed.
4Ease of repair
If modular formwork panels with aluminium frame are used, then reusability is improved, but the welding process creates dimensional variations affecting fitment of adjacent panels
Solution Approach 1:
The joining process changes from welding to mechanical connection using extruded connectors. This eliminates thermal distortion and dimensional variations caused by welding, ensuring that adjacent panels fit together accurately with parallel sides and consistent dimensions, while maintaining full reusability of the modular panels.
Solution Approach 2:
The aluminium frame is segmented with standardized connection zones that accommodate mechanical connectors. This segmentation allows panels to be assembled with high precision through repeatable mechanical connections, ensuring consistent fitment across multiple panels while maintaining reusability through easy disassembly and reassembly.
Data Source
Figure 1
Figure 2
Figure 3A~4B
AI summary
A formwork panel frame (10) includes a pair of generally parallel side beams (30) and a pair of generally parallel end beams (40) arranged perpendicular to the side beams (30) to form a generally rectangular outer frame of the formwork panel frame (10). Each end beam (40) has a hollow core (45) open at each end of the end beam (40). Four first connectors (70) join the side beams (30) to the end beams (40), with each first connector (70) having a projection (73) shaped to fit, in complementary fashion, into the hollow cores (45) of the end beams (40).