Formwork Panel with Integrated Support Grid
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Solution Overview
Problem
Conventional framed panel formwork elements are heavy, expensive, and difficult to handle due to the need for thick formwork skins and complex support structures to withstand high concrete pressures, which also complicates the replacement of worn or damaged components and impairs the nailability of the formwork skin.
Innovation Solution
A framed panel formwork element with a planar support grid integrated into the peripheral support frame, allowing for a thinner formwork skin that is more compact and cost-effective, while the support grid absorbs forces from fresh concrete pressure, enabling the use of lighter materials for the formwork skin and reducing the need for extensive stiffening profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick formwork skin and complex support structures are used to withstand high concrete pressures, then strength and rigidity are improved, but weight increases and handling becomes difficult
Solution Approach 1:
The support structure is segmented into a peripheral support frame and an integrated support grid. The support grid divides the formwork skin into multiple smaller supported areas, allowing each element to be thinner while collectively providing sufficient strength to withstand concrete pressures.
Solution Approach 2:
The formwork element combines the support frame, support grid, and formwork skin into a composite structure. This integrated design allows optimization of each component's thickness and material properties to achieve required strength with reduced overall weight compared to conventional thick-skinned designs.
2Strength
If thick formwork skin is used to withstand concrete pressure between support elements, then strength is improved, but manufacturing cost increases
Solution Approach 1:
The support grid segments the formwork skin into multiple smaller panels, each requiring less thickness to withstand pressure. This segmentation allows use of thinner, cheaper materials while maintaining overall structural strength, reducing manufacturing costs.
Solution Approach 2:
The invention changes the structural parameters by introducing a support grid, which alters the load distribution and allows reduction of the formwork skin thickness parameter, thereby reducing material costs and manufacturing expenses.
3Stability of the object's composition
If numerous stiffening profiles are attached to the formwork skin, then rigidity is improved, but device complexity increases
Solution Approach 1:
The support grid is merged with the peripheral support frame to form an integrated support structure. This combination provides the necessary rigidity through the grid's geometric configuration rather than requiring multiple separate stiffening profiles attached to the skin, simplifying the overall device.
Solution Approach 2:
Instead of adding stiffening profiles in the plane of the formwork skin, the invention introduces a support grid that spans the opening formed by the peripheral frame, utilizing the third dimension (depth/thickness) to provide rigidity through the grid's spatial configuration.
4Reliability
If numerous fastening points are used to attach longitudinal and transverse ledgers, then stabilizing effect is improved, but ease of repair worsens
Solution Approach 1:
The support grid segments the support function into multiple small contact points distributed across the formwork skin, rather than requiring numerous fastening points for separate ledgers. This segmentation maintains stabilization while simplifying repair, as the grid can be replaced as a single unit or in larger sections.
5Reliability
If longitudinal and transverse beams contact the formlining over large areas, then support effect is improved, but nailability of formlining deteriorates
Solution Approach 1:
The support grid provides support at specific localized points (the grid intersections and bars) rather than large-area contact from beams. This localized support maintains structural effectiveness while leaving most of the formwork skin surface free and accessible for nailing operations.
Data Source
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Figure 6
AI summary
The invention relates to a frame-panel formwork element (10) for producing concrete components, comprising a peripheral supporting frame (12) and a formwork lining (14) fastened to the supporting frame (12), wherein a supporting grid (22) is fastened to the supporting frame (12), on the back side of which supporting grid the formwork lining (14) lies and is supported, and wherein the thickness of the supporting grid (22) is at most half of the thickness of the supporting frame (12).