Hollow Core Formwork for One-Piece Room Module Production
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Solution Overview
Problem
Existing methods for producing room modules with three side elements and a base or ceiling element often result in the cured concrete adhering to the formwork, leading to damage during detachment and requiring separate production and connection of individual elements.
Innovation Solution
A crater-like hollow core formwork apparatus with a rectangular head element and displaceable surface elements that reduce the head element's area, allowing for the core formwork to be detached from the cured room module without damaging it, using a displacement device and tilting mechanism for easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional formwork is used for producing room modules, then the structure provides necessary support during curing, but the cured concrete adheres to the formwork causing damage during detachment
Solution Approach 1:
The formwork is divided into a head element and side elements that can be independently displaced. The head element can be lowered and the side elements moved successively in the direction of the central longitudinal axis, allowing segmented detachment from the cured concrete without causing damage.
Solution Approach 2:
The formwork elements are made dynamically movable rather than fixed. The surface elements can be displaced in the direction of the central longitudinal axis, and the head element can be lowered, enabling the formwork to adapt its position during the detachment process to prevent adhesion-related damage.
2Adaptability or versatility
If individual walls and base elements are produced separately and connected, then manufacturing flexibility is maintained, but production time and complexity increase
Solution Approach 1:
The apparatus enables one-piece production of room modules by combining the head element and side elements into a single integrated forming process. The curable compound is introduced into the hollow core formwork to produce the complete room module in one operation, eliminating the need for separate production and connection of individual elements.
3Manufacturing precision
If multiple separate apparatuses are used for producing different elements, then each element can be optimized independently, but device complexity and space requirements increase
Solution Approach 1:
The core formwork apparatus serves multiple functions: it forms the head element, side elements, and integrates them into a complete room module in one operation. The same apparatus structure is used to produce all elements of the room module, eliminating the need for multiple specialized apparatuses while maintaining manufacturing precision.
Data Source
AI summary
The invention relates to an apparatus for the one-piece production of a room module (8) having three side elements (24) and a floor element (25) and/or a ceiling element (26), wherein the apparatus takes the form of a parallelepipedal and hollow core formwork (10) around which an outer formwork (9) for the room module (8) to be produced can be arranged. The following are provided here: a) a rectangular head element (11) which consists of first planar elements (1) and second planar elements (2), b) side elements (12, 13, 14, 15) which consist of a third planar elements (3) and fourth planar elements (4) and are arranged perpendicular to the head element (11) in the edge regions thereof, wherein at least the third planar elements (3) or the fourth planar elements (4) have corner regions (17) of the side elements (12, 13, 14, 15), c) the first planar elements (1) can be lowered under the second planar elements (2) of the head element (11) and can be displaced with respect to one another and, subsequently, the second planar elements (2) can be pushed together with a reduction of the rectangular area of the head element (11), and d) the third planar elements (3) and fourth planar elements (4), which are arranged perpendicular to the head element (11), of the side elements (12, 13, 14, 15) can then be moved in succession in the direction of a centre longitudinal axis (16) of the head element (11) or the core formwork (10).