Building Panel With Integrated End Caps And Joist
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Solution Overview
Problem
Existing pre-cast concrete slab panels are heavy, difficult to maneuver, require extensive formwork, and are challenging to remove from formwork.
Innovation Solution
A building panel comprising two elongate metal C-shaped end caps, a metal joist spanning between them, and hangers coupling the joist to the end caps, with a slab cast around the joist and hangers, and end caps with coaxial holes for conduit formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pre-cast concrete slab panels utilise a periphery of metal formwork, then structural strength is improved, but device complexity and ease of manufacture deteriorate due to extensive formwork requirements
Solution Approach 1:
The patent removes the traditional peripheral metal formwork from the system. Instead of using formwork to contain concrete during casting, the invention uses end caps with internal cavities that are integrated into the final panel structure. The concrete is cast within these end caps rather than being contained by external formwork, eliminating the need for extensive formwork while maintaining structural integrity.
Solution Approach 2:
The invention merges the formwork function with the end cap structure. The end caps serve dual purposes: they provide structural support and simultaneously act as the casting mold during manufacturing. This integration eliminates the separate formwork component and simplifies the overall manufacturing process.
2Ease of manufacture
If pre-cast concrete slab panels utilise extensive metal formwork, then manufacturing capability is improved, but productivity deteriorates due to time-consuming formwork assembly and removal
Solution Approach 1:
The end caps are pre-prepared with internal cavities and reinforcement structures before the concrete casting process. This preliminary preparation eliminates the need for on-site formwork assembly, allowing for rapid panel production and installation. The hangers are also pre-attached to the end caps, further reducing assembly time during installation.
3Strength
If pre-cast concrete slab panels are designed for structural integrity, then strength is improved, but ease of operation deteriorates due to difficulty in maneuvering and removing from formwork
Solution Approach 1:
The panel is segmented into modular components: end caps with internal cavities, hangers, and concrete slab. This segmentation allows each component to be optimized independently - the end caps provide structural strength while the hollow design reduces overall weight, improving maneuverability without compromising integrity.
4Reliability
If pre-cast concrete slab panels use traditional formwork, then containment during casting is improved, but loss of time worsens due to difficult formwork removal
Solution Approach 1:
The invention extracts the containment function from external formwork and relocates it to internal end cap cavities. The concrete is cast within these pre-formed end caps, eliminating the need for external formwork removal. This resolves the time loss associated with formwork demolition while maintaining reliable casting containment.
Data Source
AI summary
A building panel for modular construction. The building panel utilises less framework for reduced complexity, materials and weight. The panel utilises features of the formwork to allow the panel to be moved easily. The panel further utilises new formwork moulds that are easier to use and create effective patterns for keying with like panels.