Formwork Panel Corner Connector for High-Load Welded Joints
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Solution Overview
Problem
Existing support structures for frame formwork panels, particularly those with diagonal struts, are complex to produce and limit their universal application due to intricate welding requirements, which complicates the transmission of large forces.
Innovation Solution
A support structure featuring corner connecting pieces welded to longitudinal and transverse edge beams, with flanges and recesses for efficient welding, allowing for a stable and simplified corner connection that can be manufactured and used across various applications, including concrete pouring and earth embankment support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If diagonal struts are welded into the corners to transfer large forces, then the force transmission capability is improved, but the production process becomes complex and universal applicability is reduced
Solution Approach 1:
The corner connection is segmented into two independent components: the edge beam with its integrated flange and recess, and the separate corner connector piece. This segmentation allows each component to be manufactured independently using standard extrusion or rolling processes, then joined through simple welding, eliminating the need for complex diagonal strut assemblies while maintaining force transmission capability.
Solution Approach 2:
The corner connector piece serves multiple functions: it connects the longitudinal and transverse edge beams, transfers forces between them, and provides a standardized welding interface through its flange and recess design. This universal corner connector can be applied to all corner positions regardless of the specific edge beam configuration, enhancing the system's adaptability.
2Productivity
If corner connectors are welded to edge beams with flanges and recesses, then the manufacturing efficiency is improved, but the welding complexity increases
Solution Approach 1:
The flange and recess features are pre-integrated into the edge beam design during the extrusion or rolling process. This preliminary action ensures that when the corner connector is welded, the welding surface is already prepared with the correct geometry and positioning features, eliminating the need for additional machining or complex fixture setup during assembly.
Solution Approach 2:
The recess in the flange acts as an intermediary feature that facilitates welding by providing a prepared receptacle for the corner connector. This intermediary structure ensures proper alignment and contact between welding surfaces, making the welding process more straightforward and reliable without requiring complex positioning procedures.
3Stability of the object's composition
If the corner connector is positioned on the front side or rear side with flanges, then the connection stability is improved, but the design complexity increases
Solution Approach 1:
The corner connector and edge beam features are designed with asymmetric flange and recess configurations that provide inherent directional stability. The asymmetry ensures proper orientation during assembly and creates a mechanically stable connection that resists forces from the formwork, while the standardized asymmetric design can be consistently reproduced without requiring complex variable positioning.
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 solution provides a stable, efficient, and versatile support structure that can handle large forces while simplifying the production process, enabling universal application in formwork panels and other construction scenarios.
Implementation Method 1
a corner connector is provided, which is welded to the two respective edge beams
Data Source
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AI summary
Support structure for a frame formwork panel, comprising a support structure (2) and a formwork skin (34) connected to the support structure (2), wherein the support structure (2) comprises two longitudinal edge beams (4) and two transverse edge beams (6), characterized in that in at least one subnumber of the corner regions of the support structure (2), where a longitudinal edge beam (4) and a transverse edge beam (6) meet, a corner connecting piece (10) is provided which is welded to the two edge beams (4,6) in question.