One-Piece Metal Formwork Frame with Central Rib
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Solution Overview
Problem
The existing formwork devices for constructing walls are costly to manufacture and assemble, require specific tools, and are prone to weaknesses and obstructions due to excess welds, which can lead to gaps between the support wall and formwork, allowing laitance and concrete drips, and complicating the application of facade plaster.
Innovation Solution
A one-piece metal frame with a triangular configuration and internal ribbing is produced using a cutting-stamping machine, featuring pre-cut notches and a central rib to guide an adjustment zipper, allowing for simplified assembly and reduced manufacturing costs by eliminating independent components and welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a multi-component frame with welding and folding operations is used, then the formwork device achieves structural integrity and functionality, but the manufacturing cost and assembly complexity increase significantly
Solution Approach 1:
The patent combines multiple separate components (frame, adjustment rod, folding elements) into a single integrated metal strip structure. The adjustment rod is formed as an integral part of the metal strip through sequential folding operations, eliminating the need for separate welding or assembly operations while maintaining structural integrity and adjustability.
Solution Approach 2:
The metal strip is divided into functional zones that are sequentially folded to create distinct structural elements. The strip is segmented into a frame portion, a central rib portion, and wing portions, each folded into its final configuration through controlled folding operations at specific locations.
2Strength
If a threaded rod with thickness of at least 6 mm is used for adjustment, then the structural strength is improved, but the formwork slice gap increases allowing laitance and concrete drips
Solution Approach 1:
The patent creates a central rib with reduced thickness (less than 6 mm) specifically at the location where the adjustment rod passes through. This localized thinning allows the adjustment rod to have minimal thickness, preventing formwork gaps and laitance infiltration, while the overall frame structure maintains sufficient strength through its geometric configuration and material distribution.
Solution Approach 2:
The patent transitions from a solid thick rod to a folded metal strip configuration that creates a central rib with hollow or reduced-section geometry. This dimensional change allows the adjustment mechanism to pass through a thinner profile while maintaining structural adequacy through the folded configuration's inherent stiffness.
3Strength
If multiple manufacturing operations including welding are performed, then the frame achieves required structural properties, but the manufacturing cost and production time increase
Solution Approach 1:
The patent performs all necessary forming operations (cutting, notching, folding) on the metal strip in a sequential manner before final assembly. The frame, central rib, and adjustment rod are all pre-formed through folding operations in advance, eliminating the need for costly welding operations during final assembly and reducing manufacturing complexity.
Solution Approach 2:
The metal strip structure is designed to form its own structural elements through self-contained folding operations. The frame folds into its final configuration, the central rib forms its guiding structure, and the adjustment rod creates its adjustment mechanism, all through sequential folding of the same continuous metal strip without requiring external welding or fastening operations.
4Ease of manufacture
If welds are performed during assembly, then the components are joined together, but excess weld accretions may obstruct the adjustment rod passage and create areas of weakness
Solution Approach 1:
The patent extracts the adjustment rod function from a separate welded component and integrates it as an integral folded portion of the metal strip. This eliminates welding operations entirely, removing the source of weld accretions that could obstruct the adjustment rod passage or create weak points in the structure.
Solution Approach 2:
The frame structure and adjustment rod mechanism are merged into a single continuous metal strip. The adjustment rod is formed as an integral folded portion of the frame itself, eliminating the need for separate components and welding operations, thereby eliminating weld-related defects and improving assembly reliability.
Data Source
Figure 1~3
Figure 4~7
AI summary
The method involves forming a pre-cur notch on a side of a transversal median part (10c) of a module, and progressive folding forming a part of a transversal progressive rib, where the rib is constituted of a guide of an adjusting pull rod. A longitudinal fold of parts of the module is formed over the rib for producing a support plane perpendicular to a plane of the module. The module is separated. An independent claim is also included for a carcass comprising a transversal median part.