Stay-in-place formwork panels with convexities
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Solution Overview
Problem
Prior art modular stay-in-place formwork systems experience deformation issues such as 'pillowing' and 'bellying' due to the weight and pressure of liquid concrete, leading to unsightly appearances, panel fatigue, and reduced structural integrity.
Innovation Solution
The use of elongated panels with inwardly projecting convexities and brace elements that extend between the outer and inner surfaces, providing a truss-like configuration to redirect outward forces and minimize deformation, along with anchor components for enhanced stability and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If modular stay-in-place formwork panels are used to fabricate concrete structures, then construction efficiency and modularity are improved, but panel deformation (pillowing and bellying) occurs due to liquid concrete weight and pressure
Solution Approach 1:
The formwork system is divided into modular panels connected by connector components, allowing each panel to be independently designed with anti-deformation features while maintaining overall structural integrity. The segmentation enables targeted reinforcement at specific locations without compromising the entire formwork system.
Solution Approach 2:
Inwardly projecting convexities are added to the inner surface of panels to create a curved configuration that redirects outward forces from liquid concrete. This curvature transforms the deformation pattern, converting potential panel bowing into controlled inward movement that maintains panel flatness and prevents pillowing.
2Shape
If support panels and tensioning panels are added to reduce pillowing, then panel deformation is reduced to some degree, but the formwork system complexity increases
Solution Approach 1:
Anti-deformation features (convexities and brace elements) are integrated directly into the wall panels themselves, merging the functions of the panel and its reinforcement structure. This eliminates the need for separate support panels and tensioning panels, reducing overall system complexity while maintaining deformation control.
Solution Approach 2:
The connector components serve multiple functions: joining adjacent panels together and simultaneously providing brace elements that prevent deformation. This multi-functionality reduces the number of separate components needed, simplifying the formwork system while maintaining structural integrity.
3Shape
If inwardly projecting convexities and brace elements are added to panels, then panel deformation is significantly reduced, but manufacturing complexity increases
Solution Approach 1:
The inner surface of panels is modified by adding convexities with specific geometric parameters (radius of curvature, projection depth) that can be incorporated during standard manufacturing processes. These parameter changes are designed to be compatible with existing manufacturing capabilities while providing the necessary anti-deformation properties.
Solution Approach 2:
The formwork panels utilize composite construction combining rigid materials (such as extruded polymers or metals) with integrated geometric features. This composite approach allows complex shapes like convexities and brace elements to be manufactured as single integrated components rather than assembled parts, simplifying production.
Data Source
AI summary
A formwork apparatus for forming a concrete structure comprises a plurality of elongated panels comprising connector components at their transverse edges for connecting to one another in edge-adjacent relationship. Each one of the elongated panels comprises an outer surface that extends between its transverse edges and an inner surface that extends between its transverse edges at a location inwardly spaced apart from the outer surface. The inner surface comprises one or more inwardly projecting convexities that extend between the transverse edges. The inwardly projecting convexities may comprise arcuate-shaped surfaces. The inwardly projecting convexities may comprise a plurality of transversely adjacent convexities. There may be brace elements that extend part way between or all the way between the outer and inner surfaces.