Cladding Element with Sealed Mortar Layers for Corrosion Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing formwork elements are difficult to process, aesthetically unpleasing, and prone to moisture penetration leading to corrosion and damage, especially when used in building structures with steel reinforcement.
Innovation Solution
A formwork element comprising a sealing layer between two formwork layers, each made of a mixture composition, particularly mortar, ensuring moisture-tight separation and easy processing, with optional cavities and reinforcing elements to enhance stability and aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If formwork elements have an epoxy coating as their outermost layer, then moisture protection is improved, but processing difficulty increases and aesthetic appearance deteriorates
Solution Approach 1:
The formwork element is divided into multiple layers: a first formwork layer in contact with the building structure, a sealing layer for moisture protection, and a second formwork layer as the outer surface. This segmentation allows each layer to have specialized functions - the sealing layer provides moisture protection while the second formwork layer provides an aesthetically pleasing and easily processable surface, resolving the contradiction between moisture protection and processing ease.
2Temperature
If formwork elements contain embedded insulation elements, then thermal insulation is improved, but waterproofing performance deteriorates
Solution Approach 1:
The sealing layer acts as an intermediary between the first formwork layer and the second formwork layer, creating a continuous moisture-tight barrier that prevents water penetration even when insulation elements are embedded within the formwork structure. This intermediary layer ensures waterproofing performance is maintained while allowing thermal insulation elements to be integrated.
3Ease of manufacture
If formwork elements use a single-layer structure, then manufacturing simplicity is improved, but moisture protection capability deteriorates
Solution Approach 1:
The formwork element uses a composite structure with at least three different layers: a first formwork layer, a sealing layer, and a second formwork layer. Each layer can be made from appropriate materials optimized for its specific function - the sealing layer provides superior moisture protection while the formwork layers provide structural integrity and surface quality, achieving enhanced moisture protection while remaining manufacturable.
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
A formwork element (1) comprising a) a sealing layer (2) and b) a first (3) and a second (3') formwork layer, each of the first (3) and the second (3') formwork layer comprising a mixture composition, in particular mortar, wherein the sealing layer (2) is present between the first (3) and the second (3') formwork layer, so that the first (3) and the second (3') formwork layer are separated from each other in a moisture-tight manner.