Concrete Depression Form System Using Removable Guide Rails

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Solution Overview

Problem

Existing concrete depression form systems are labor-intensive, require experienced workers, and involve complex post-curing processes, with support towers often protruding from the slab or needing removal before full curing.

Innovation Solution

A concrete depression form system utilizing removable, horizontally disposed guide rails mounted on discrete, height-adjustable support towers made of folded sheet metal or rigid plastic, which are embedded in the concrete after curing, eliminating the need for post-curing processing and ensuring no support tower protrusion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional wooden boards and supports are used as rails, then the system is simple to manufacture, but the installation is very labor intensive and requires experienced workers

Engineering Contradiction:

Improvesimplicity of manufacturingVSAvoidease of installation

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The support system is divided into discrete support towers rather than continuous wooden supports. Each tower is an independent unit that can be individually positioned and adjusted, eliminating the need for complex continuous support structures and reducing installation complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support towers incorporate height-adjustable mechanisms with multiple positioning notches, allowing dynamic adjustment of rail height during installation. This adaptability enables workers to easily set different heights without requiring experienced judgment or complex procedures.

Inventive Principle:

Principle #15Dynamics

2Ease of manufacture

If wooden supports are used, then the material is easy to work with, but the supports must be removed from the slab prior to complete hardening with additional processing required

Engineering Contradiction:

Improveease of material processingVSAvoidtime for post-curing processing

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The support towers are designed as sacrificial consumable components made from inexpensive materials like folded sheet metal or rigid plastic. They are intentionally left embedded in the concrete slab after curing, eliminating the need for removal and post-curing processing entirely.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The rail member is extracted as a removable component while the support towers remain embedded. This separation allows the rails to be easily removed after curing while the support towers serve their final purpose as embedded structural elements, eliminating additional processing steps.

Inventive Principle:

Principle #2Taking out (Extraction)

3Strength

If plastic or metal supports are used, then the materials are durable, but post-curing processes such as cutting or grinding are required to remove exposed portions

Engineering Contradiction:

Improvedurability of supportsVSAvoidease of post-curing processing

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The support towers are designed with asymmetric geometry where the tower body extends above the rail but the exposed portions are intentionally configured to be flush with or below the finished slab surface. This asymmetric design eliminates the need for symmetric post-curing processing like cutting or grinding.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Ease of operation

If support towers extend outward from the slab surfaces, then the structure is easier to assemble, but the finished slab requires additional processing to remove protrusions

Engineering Contradiction:

Improveease of assemblyVSAvoidtime for post-curing processing

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The support towers are pre-configured with height adjustments and notch positions that ensure proper embedding depth before the concrete is poured. This preliminary positioning ensures that no post-curing processing is needed to remove protrusions, as the towers are correctly positioned from the start.

Inventive Principle:

Principle #10Preliminary action

5Manufacturing precision

If experienced workers are required for proper set-up, then the installation precision can be maintained, but the productivity and construction speed decrease

Engineering Contradiction:

Improveprecision of slab formationVSAvoidconstruction speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system allows easy adjustment of key parameters such as rail height and support tower positioning through mechanical notches and adjustable mechanisms. This parameter adjustability maintains precision while enabling workers of varying skill levels to achieve proper setup, thereby increasing productivity.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS10100539B2Concrete depression form system and method

Publication Date: 2018.10.16 RAPID PRO SAFE LLC

AI summary

A concrete depression form system and method having a rail that is readily removable from sacrificial support towers after the concrete has sufficiently cured, leaving a slab having an elevated interior slab surface and a depressed or lower exterior slab surface, the support towers being structured such that concrete flow is only minimally impeded and such that no portion of the support towers extends outwardly from the slab surfaces.