Permanent Formwork Modules With Screw-Assembled Half-Spacers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing lost formwork elements for concrete swimming pool walls require manual welding of half-spacers, leading to high manufacturing costs and variability in weld quality, which can result in structural disorders and deformation under concrete pressure, affecting the wall's flatness and mechanical strength.
Innovation Solution
The use of modules with half-spacers featuring proximal bores for screw assembly, providing high mechanical resistance and rigidity, allowing assembly by unskilled personnel with a screwdriver, and enabling unassembled module storage with reduced footprint, while minimizing material perforation and oxidation risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual welding is used to assemble half-spacers, then the formwork element can be constructed, but the manufacturing cost increases and weld quality becomes variable
Solution Approach 1:
The patent replaces the welding process (thermal/chemical system) with a mechanical screw assembly system. The half-spacers are equipped with proximal bores that receive assembly screws, transforming the joining mechanism from welding to mechanical fastening. This substitution eliminates weld quality variability while maintaining structural integrity, as screws provide consistent mechanical connection without the complexities of weld procedure control.
2Productivity
If welding is used to join half-spacers, then the modules can be assembled, but the labor cost and manufacturing complexity increase
Solution Approach 1:
The half-spacers are designed with self-aligning proximal bores that guide the assembly screws directly into position. This self-service feature eliminates the need for complex welding fixtures or specialized equipment, allowing unskilled personnel to assemble the modules using only a screwdriver or electric screwdriver. The design inherently provides alignment and positioning functions that would otherwise require complex external tools.
3Strength
If welding is used to ensure structural strength, then the formwork can withstand concrete pressure, but the risk of deformation under pressure increases due to weld variability
Solution Approach 1:
The patent changes the joining parameter from weld penetration depth and temperature control to screw insertion depth and tightening torque. The assembly screws engage with threaded portions in the proximal bores, providing controlled mechanical fastening with precise engagement parameters. This parameter change ensures consistent clamping force distribution across all half-spacers, preventing localized deformations that could compromise wall flatness under concrete pressure.
4Reliability
If modules are delivered pre-assembled to ensure quality, then the assembly quality improves, but the storage volume and delivery cost increase
Solution Approach 1:
The patent segments the formwork system into modular panels with integrated half-spacers that are designed for easy field assembly. Each panel is self-contained with the necessary joining features (proximal bores in half-spacers), allowing quality control at the panel manufacturing stage while maintaining compact storage. The segmentation enables panels to be stored in a nested or stacked configuration with reduced footprint compared to fully pre-assembled structures.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The module has a set of semi-cross-bars (20) distributed on a back side (5) of a rectangular panel (3) by extending perpendicular to the panel. The semi-cross-bars are placed in four rows parallel to an upper edge of the panel. Each semi-cross-bar has a male and/or female embedding element at the level of its distal end for engagement in a complimentary embedding element of a corresponding semi-cross-bar during the assembly of the module with another module. The semi-cross-bars have a proximal bore (22) receiving an assembling screw and emerge out at the level of a front side (4) of the panel. An independent claim is also included for a permanent formwork element comprising two identical modules embedded with each other at the level of their semi-cross-bars and assembled by a set of screws engaged by a set of screws engaged in proximal bores of embedded semi-cross-bars.