Bridge Member Spanning Form Liner Joints
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Solution Overview
Problem
Existing form liner systems using multiple form liners often result in discontinuous and uneven concrete walls due to inadequate sealing and warping, leading to visible seams and imperfections, which require cosmetic corrections like caulking and grinding.
Innovation Solution
A form liner system comprising a first and second form liner with bridge members that create a collective cell, minimizing visible seams by spanning the connection between liners and using adhesive bridge members for securement, allowing for seamless texture continuity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple form liners are used to create large continuous walls, then the wall size and coverage area are improved, but visible seams and discontinuities appear at the joint areas
Solution Approach 1:
A bridge member is introduced as an intermediary element between adjacent form liners. The bridge member spans the joint area and is configured to be submerged in the concrete slurry, creating a continuous surface that masks the discontinuity between multiple form liners. This mediator element allows multiple liners to be used while maintaining the appearance of a single continuous form liner.
2Stability of the object's composition
If form liners are secured to the casting bed using fasteners, then the form liner stability is improved, but the fasteners create visible distortions and imperfections on the wall surface
Solution Approach 1:
The fastening function is extracted from the form liner system. Instead of securing form liners to the casting bed using visible fasteners, the bridge member is used to connect adjacent form liners at their joints. This removes the need for fasteners that would create visible distortions on the wall surface, while still providing necessary stability and continuity.
3Manufacturing precision
If caulk is applied to joint areas between form liners, then the visual appearance is improved, but the labor intensity and time required increase
Solution Approach 1:
The bridge member is installed on the form liners before the concrete pouring process. This preliminary action creates the continuous surface appearance in advance, eliminating the need for subsequent cosmetic work such as caulking. The bridge member is positioned and secured prior to concrete placement, so the continuous appearance is achieved during the main construction process rather than requiring post-construction cosmetic corrections.
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
The system enables the creation of a continuous texture appearance as if made from a single form liner, reducing visible seams and imperfections, and securing the liners without distorting the wall surface, thus eliminating the need for extensive cosmetic corrections.
Implementation Method 1
adhesive bridge members for securement
Data Source
AI summary
A form liner system comprises a first form liner, a second form liner and a bridge member. Each form liner comprises a plurality of raised portions defining a plurality of cells and at least one partial cell. The form liners are arranged such that the partial cells form a collective cell. The bridge member can be oriented in said collective cell, wherein a first portion of the bridge member is oriented in the first liner partial cell and a second portion of the bridge member is oriented in the second liner partial cell.