Formwork Corner Connector with Prongs and Locking Grooves
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Solution Overview
Problem
Existing formwork panel systems face challenges with rigidity and squareness due to joint rotation, require numerous fasteners and supplemental parts, and are costly and labor-intensive to assemble, especially when using dissimilar materials.
Innovation Solution
A corner element with prongs and locking grooves, combined with direct tension lockbolts, allows for secure connection of dissimilar materials, reducing the number of fasteners needed and enabling assembly with improved rigidity and alignment without additional obstructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fasteners are used to join dissimilar materials, then connection is achieved, but joint rotation occurs reducing rigidity and squareness
Solution Approach 1:
A metal plate is introduced as an intermediary component between dissimilar materials (e.g., aluminum and steel). The plate is fastened to both materials using standard fasteners, creating a mechanical bridge that prevents joint rotation while maintaining connection strength. This mediator absorbs the clearance requirements of fasteners without allowing relative rotation between the connected parts.
Solution Approach 2:
The connection system is divided into separate functional components: the metal plate serves as a rigid connector, while separate fasteners handle the joining function. This segmentation allows each component to optimize its specific function - the plate maintains rigidity and squareness, while the fasteners provide secure attachment to dissimilar materials.
2Reliability
If multiple fasteners and supplemental parts are used, then stable assembly is achieved, but device complexity and cost increase
Solution Approach 1:
The metal plate performs multiple functions simultaneously: it acts as a connector between dissimilar materials, provides structural rigidity, ensures squareness at joints, and serves as a mounting surface for fasteners. This multi-functionality eliminates the need for separate supplemental parts like compensation walers, reducing overall device complexity while maintaining assembly stability.
Solution Approach 2:
The invention merges the functions of connection, rigidity maintenance, and alignment into a single metal plate component. By combining these functions that were previously handled by multiple separate parts, the system achieves stable assembly with fewer components, directly reducing device complexity and cost.
3Manufacturing precision
If supplemental parts like compensation walers are added, then alignment is maintained, but ease of operation and assembly efficiency decrease
Solution Approach 1:
The metal plate provides alignment functionality through its rigid structure and precise geometry, eliminating the need for separate compensation walers. The plate's design inherently maintains panel alignment while also providing connection and rigidity functions, thereby improving assembly efficiency by reducing the number of components to be handled and positioned.
Data Source
AI summary
A formwork panel system comprising corner connectors comprising a first body portion and a second body portion forming a 90° angle, at least one opening in the first body portion, a first prong extending from the first body portion, and a second prong extending from the second body portion, wherein the corner connectors and side rails form a rigid body connected to a first panel. The panel system where the at least one opening secures the corner connector to a corner connector of a second panel via a bolt and rectangular nut member. The panel system further comprising plurality of fasteners configured to be inserted into prong openings wherein the plurality of fasteners are configured to compress the side rails about the prongs.