Flexible Layered Form Elements for Reusable 3D Concrete Formwork

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional formwork systems require irreversibly deformed elements to produce three-dimensionally shaped concrete parts, which are costly and not reusable.

Innovation Solution

A form element comprising flexible layers that can be reversibly deformed into various shapes and stiffened in a deformed position, using magnetic or frictional connections, vacuum pressure, or inflatable devices to create a stable formwork.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional rigid plate elements are used to produce three-dimensionally deformed concrete parts, then the desired shape can be achieved, but the formwork elements must be irreversibly deformed and cannot be reused

Engineering Contradiction:

Improveshape adaptabilityVSAvoidreusability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The form element transitions from a rigid static structure to a dynamic system with two distinct states: a flexible first state for deformation and shaping, and a stiffened second state for formwork operation. This dynamic state change allows the same element to adapt to different shapes while maintaining structural integrity during use, enabling both shape adaptability and reusability

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The form element's physical parameters (flexibility, stiffness, strength) are changed between two states through a transition mechanism. In the first state, the element exhibits flexible properties allowing three-dimensional deformation. In the second state, the element is stiffened and solidified to withstand concrete pressure. This parameter change enables the element to be reused multiple times while achieving various shapes

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If irreversibly deformed formwork elements are used, then three-dimensional shapes can be produced, but the elements are costly and cannot be reused

Engineering Contradiction:

Improveshape accuracyVSAvoidcost-effectiveness

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

Instead of discarding the form element after single-use irreversible deformation, the invention enables recovery of the element by transitioning it back to its flexible first state. The element can then be re-deformed into the desired shape and reused multiple times, significantly improving cost-effectiveness while maintaining shape accuracy through controlled deformation and stiffening cycles

Inventive Principle:

Principle #34Discarding and recovering

3Stability of the object's composition

If conventional formwork systems are used, then structural stability is achieved, but the elements cannot be easily deformed three-dimensionally

Engineering Contradiction:

Improveformwork stabilityVSAvoiddeformability

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The form element employs dynamic state transition to resolve the contradiction between stability and deformability. In the first state, the element is flexible and easily deformable into three-dimensional shapes. In the second state, the element is stiffened and solidified to provide the structural stability required for formwork. This dynamic switching allows both high deformability during shaping and high stability during concrete pouring

Inventive Principle:

Principle #15Dynamics

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

Enables cost-effective and environmentally friendly production of three-dimensional concrete parts by allowing the form element to be reused multiple times and adapt to specific shapes on-site.

Implementation Method 1

In the second state, the form element may in particular be stiffened and solidified such that it can withstand the occurring forces

Methodology Applied

Scientific EffectMagnetic force: Magnetism

Implementation Method 2

using magnetic or frictional connections, vacuum pressure, or inflatable devices to create a stable formwork

Methodology Applied

Scientific EffectVacuum pressure: Vacuum

Implementation Method 3

using magnetic or frictional connections, vacuum pressure, or inflatable devices to create a stable formwork

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 4

using magnetic or frictional connections, vacuum pressure, or inflatable devices to create a stable formwork

Methodology Applied

Scientific EffectInflation pressure: Pressure Increase

Data Source

PatentUS12448792B2Form element, arrangement of the form element and method for forming at least one part of a formwork for a concrete part with the form element

Publication Date: 2025.10.21 NAJJAR RAMES

AI summary

The invention relates to a form element (1), an arrangement comprising such a form element (1) and a method for forming at least part of a formwork for a concrete part using this form element (1), wherein the form element (1) is flexibly three-dimensionally deformable in its first state, and wherein the form element (1) is stiffened and solidified in its second state, in particular in a deformed position of the form element (1), wherein the form element (1) comprises at least two flexible layers (2), which are arranged superimposed in a planar manner, and wherein the layers (2) are connected to each other, in particular reversibly, in the second state to solidify the form element (1).