Formwork Element with U-Shaped Stirrup Connectors
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Solution Overview
Problem
Existing formwork elements face challenges in transporting them over long distances due to high empty space and complex assembly processes, leading to increased costs and inefficiencies.
Innovation Solution
The formwork elements are connected using U-shaped stirrups with push-in brackets that can be easily inserted during assembly, featuring recessed webs and barbed tabs for secure anchoring, allowing for quick and stable assembly without hindering adjacent connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If sheet metal webs are firmly embedded in foam to connect side plates, then structural stability is improved, but transport volume efficiency deteriorates due to high empty space between formwork elements
Solution Approach 1:
The formwork element is divided into separate modular components: side plates, connecting elements with stirrups, and foam insulation pieces. This segmentation allows each component to be optimized independently and packed efficiently during transport, reducing empty space while maintaining structural stability through precise reassembly using the connecting elements with their stirrup-based anchoring system.
2Stability of the object's composition
If complex connecting elements with tabs and slots are used to ensure stability, then structural integrity is improved, but assembly complexity increases
Solution Approach 1:
The connecting elements incorporate self-aligning and self-securing features through the stirrup design that automatically engages with the side plates. The stirrups provide inherent mechanical interlocking that guides assembly without requiring complex alignment procedures or additional fastening steps, thereby maintaining structural integrity while simplifying the assembly process.
3Productivity
If U-shaped stirrups with barbed tabs are used to connect side plates, then assembly speed is improved, but manufacturing complexity increases
Solution Approach 1:
The stirrup geometry and barb configurations are optimized within standard manufacturing capabilities to achieve rapid assembly. By carefully selecting stirrup dimensions, barb angles, and placement patterns, the design achieves fast self-securing assembly while remaining compatible with conventional stamping and forming processes, thus balancing assembly speed with manufacturing simplicity.
Data Source
Figure 1~3
Figure 4~5
AI summary
The formwork element (1) has two heat insulating end plates (2, 3) made of plastic and arranged parallel to each other at a distance from each other. The end plates have a protrusion (6) and a slot for connection of the element with another formwork element. Multiple connecting elements i.e. U-shaped plug clamp, having a straight bar (14) are arranged between the end plates. The connecting elements are fixed with a flap in a slot formed at an upper quoin (4) or a lower quoin (5) of the end plates.