Collapsible Formwork with Hinged Connectors

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Solution Overview

Problem

Conventional 'lost' formwork is not economical due to high production costs, requires significant manual labor, is bulky, difficult to transport, and often uses environmentally damaging foam panels and adhesives, limiting its practical use.

Innovation Solution

A collapsible formwork element with hinged connector members that allows for expansion and collapse, enabling space-saving transportation and on-site assembly, featuring snap-lock mechanisms and extruded polymer components for cost-effective manufacturing and reduced environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional lost formwork is produced from injection moulded parts made from multiple materials, then the formwork can achieve required structural integrity, but production costs increase and manufacturing complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoidproduction cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The connector member is formed from a composite material comprising a rigid outer layer and a flexible inner layer, allowing the single-component connector to provide both structural strength and hinge functionality, thereby reducing manufacturing complexity and cost while maintaining structural integrity

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The connector member is segmented into distinct functional zones: a rigid outer layer for structural support and a flexible inner layer for hinge action, enabling the single component to fulfill multiple functions that previously required multiple materials and assembly steps

Inventive Principle:

Principle #1Segmentation

2Strength

If conventional lost formwork is made bulky to maintain structural integrity, then strength is improved, but transportation difficulty increases and storage space requirements increase

Engineering Contradiction:

Improvestructural integrityVSAvoidtransportation volume

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The connector member incorporates hinge portions that enable the formwork element to dynamically change its configuration between expanded (for structural integrity) and collapsed (for compact transportation), allowing the same structure to fulfill opposing requirements at different operational stages

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The collapsible design allows the formwork element to be nested into a compact configuration for transportation, with the connector members folding to reduce the overall volume while maintaining the ability to expand to full size for structural application

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of manufacture

If conventional lost formwork uses foam panels and adhesives, then assembly is achieved, but environmental harm increases and manufacturing complexity increases

Engineering Contradiction:

Improveassembly capabilityVSAvoidenvironmental harm

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The invention extracts and eliminates the need for separate foam panels and adhesives by integrating the hinge functionality directly into the connector member through the flexible inner layer, thereby removing harmful materials while maintaining assembly capability

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The connector member merges the functions of structural connection and hinge movement into a single integrated component, eliminating the need for separate foam panels and adhesives, thereby reducing environmental harm and manufacturing complexity

Inventive Principle:

Principle #5Merging (Combining)

4Strength

If connector members are made rigid to provide structural support, then strength is improved, but hinge functionality is lost

Engineering Contradiction:

Improvestructural supportVSAvoidhinge functionality

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The connector member uses a composite structure with a rigid outer layer providing structural support and a flexible inner layer providing hinge functionality, allowing both strength and adaptability to coexist within a single component

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The connector member has different local properties: the outer layer is rigid for structural support while the inner layer is flexible for hinge action, allowing each part of the connector to have the quality needed for its specific function

Inventive Principle:

Principle #3Local quality

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 collapsible formwork element significantly reduces transportation costs and on-site storage needs, allows for efficient assembly, and minimizes environmental impact while maintaining structural integrity and ease of use.

Implementation Method 1

the hinge portions are formed of a material that is more flexible than the material forming the reminder of the connector member, which is substantially rigid, so as to provide a hinge type action

Methodology Applied

Scientific EffectFlexibility: Elasticity

Data Source

PatentUS20240254764A1formwork

Publication Date: 2024.08.01 RISE FORM PTY LTD

AI summary

A collapsible formwork element, the element including: a pair of opposing side wall panels; and at least one connector member extending between the side wall panels, wherein the formwork element is movable between an expanded configuration, wherein the opposing panels are spaced apart, and a collapsed configuration, wherein the opposing panels are relatively closer together.