Cast Construction Connector and Support Frame Assembly
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Solution Overview
Problem
Current construction methods for cast structures like walls, ceilings, and beams are time-consuming, expensive, and environmentally polluting, requiring multiple stages and significant logistical efforts, with many stages performed by different professionals and generating dust and pollution.
Innovation Solution
A method and system using a unique support frame and connectors to set up parallel boards for casting, allowing concrete to be poured between them, with optional reinforcement, insulation, and coatings applied directly to the boards, which can be removed post-curing for uncoated or single-sided coated structures, utilizing specialized connectors and a kit of support frames for efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional multi-stage construction methods are used for cast structures, then structural quality and coating application are ensured, but construction time and labor requirements increase significantly
Solution Approach 1:
The patent combines multiple construction stages into a single integrated process. The support frame and boards are assembled with all necessary components (reinforcement, insulation, coatings) in one operation, then concrete is poured in a single casting action. This merging of stages eliminates the sequential time loss of traditional multi-stage construction while maintaining structural quality through the integrated design.
Solution Approach 2:
The support frame, boards, reinforcement elements, insulation materials, and surface coatings are all prepared and positioned in advance before concrete pouring. This preliminary assembly of all components allows the actual construction to be completed in a single casting operation, dramatically reducing construction time while ensuring quality through pre-positioned elements.
2Manufacturing precision
If traditional construction methods with multiple stages are used, then detailed coating application is achieved, but labor intensity and construction cost increase
Solution Approach 1:
The patent merges the application of multiple coatings and surface treatments into a single integrated assembly process. Different types of boards with various coatings are pre-applied and secured to the support frame in one operation, eliminating the need for sequential coating applications by different workers. This maintains coating quality while significantly improving construction efficiency.
Solution Approach 2:
The support frame system serves multiple functions simultaneously: it provides structural support, holds reinforcement elements, secures insulation materials, and attaches coated boards. This multi-functionality eliminates the need for separate specialized labor for each function, reducing overall labor intensity and construction cost while maintaining detailed coating application quality.
3Reliability
If traditional multi-stage construction is used, then structural completeness is ensured, but environmental pollution and dust generation increase
Solution Approach 1:
All construction materials and components are prepared and assembled in controlled environments before being transported to the final construction site. The support frame, boards, reinforcement, and insulation are pre-assembled with minimal dust generation. This preliminary action reduces on-site construction activity and associated pollution while ensuring structural completeness through pre-positioned components.
Solution Approach 2:
The patent extracts the polluting construction activities from the final assembly process. The support frame and components are manufactured and assembled separately in controlled environments, then transported to the site for final integration. This extraction of construction activities from the final stage reduces environmental pollution and dust generation while maintaining structural completeness.
4Manufacturing precision
If traditional construction methods are used, then detailed preparation and finishing are achieved, but logistical complexity and equipment requirements increase
Solution Approach 1:
The patent segments the construction system into modular components: the support frame, various types of boards (plaster, stone, insulation), reinforcement elements, and coatings. Each component can be manufactured, prepared, and transported independently, then assembled at the site. This segmentation reduces logistical complexity by allowing standardized transportation and storage of individual components while maintaining detailed preparation and finishing quality.
Solution Approach 2:
The support frame system is designed as a universal platform that can accommodate different types of boards, coatings, and insulation materials. This multi-functionality simplifies logistics by using a single standardized support structure for various applications, reducing the need for specialized equipment and complex logistical arrangements while maintaining detailed preparation and finishing capabilities.
Data Source
AI summary
The invention relates to a method for producing cast structures, and a set of connectors for connecting a pair of opposed, spaced apart boards which are useful in said method. A kit of elements useful as support frames in the production of the cast structures is also provided.