Building Component Forming Apparatus with Resilient Clips
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Solution Overview
Problem
Existing methods for forming building components with settable materials and facing members, such as concrete panels with bricks or tiles, face challenges in accurately locating and securing the facing members, managing size variations, achieving a good bond without the settable material reaching the front face, and minimizing post-moulding work, especially when panels are not flat or require features like windows.
Innovation Solution
An apparatus comprising a base member with a regular array of through holes for clip members, which engage with facing members to hold them in position and include a resilient clip head that can flex to accommodate size variations, along with a sealing member to prevent settable material from reaching the front face, and frangible formations for easy release after setting, allowing for accurate pattern formation and secure attachment of facing members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If facing members are secured to the mould using traditional methods (sand, gluing, sealant), then the facing members are held in position during moulding, but the settable material may still reach the front face or the facing members are not securely retained
Solution Approach 1:
A resilient sealing member is introduced as an intermediary element between the facing members and the settable material. This sealing member prevents the settable material from reaching the front face of the facing members while allowing the facing members to be securely held in position by the clips during moulding.
Solution Approach 2:
The apparatus divides the retention function into separate components: clips for holding facing members in position and a sealing member for preventing material intrusion. This segmentation allows each component to optimize its specific function without compromising the other.
2Ease of manufacture
If facing members are cut prior to use (e.g., using water cooled blades), then the facing members can be sized appropriately, but the products become wet and require additional drying and post-moulding removal work
Solution Approach 1:
The clips are designed as disposable components that are easy to remove after moulding. They are sacrificed to avoid the need for complex removal processes and post-moulding work, making the overall process more efficient despite the slight waste of the clip material.
3Adaptability or versatility
If the mould is used to form panels with varied patterns (windows, corners, non-flat structures), then the panels can meet architectural requirements, but the facing members must be accurately located and held in position throughout the process
Solution Approach 1:
The resilient nature of both the clips and sealing member allows the system to adapt to various panel configurations and facing member size variations while maintaining secure retention and precise positioning throughout the moulding process.
4Strength
If a good bond between settable material and facing members is required, then the facing members must be held close to the mould surface, but the settable material must not reach the front face of the facing members
Solution Approach 1:
The sealing member serves as a mediator that creates a controlled barrier between the settable material and the facing members. It allows the facing members to be positioned close to the mould surface for bonding while preventing material intrusion to the front face.
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 apparatus ensures accurate and secure attachment of facing members, prevents settable material from reaching the front face, and allows for minimal post-moulding work, enabling efficient production of building components with varied patterns and features, including corners and openings, while allowing for reuse of the base member and easy removal of clips.
Implementation Method 1
Each clip member also having a head engageable against a facing member to urge the facing member against the base member... resilient clip head that can flex to accommodate size variations
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
Apparatus (10) usable in forming a building component of a settable material such as concrete with a plurality of facing members (24) such as bricks. The apparatus comprises a base member (12) in the form of a steel plate with a regular array of mounting holes (14) which can receive clip members (26) to support the facing members (24) in position during casting of the concrete.