Honeycomb Polymer Formwork Panels

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Solution Overview

Problem

Existing formwork facing materials, such as steel, aluminum, and plywood, face issues with durability, water intrusion, weight, and cost, while composite plastic facings offer improved durability but are heavier and more expensive.

Innovation Solution

A composite panel comprising a honeycomb core sandwiched between two uni-directional continuous fiber reinforced polymer sheets, which are thermally bonded and feature a polypropylene film layer for improved durability and water resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If steel is used for formwork facing, then durability and strength are improved, but weight increases and rust resistance deteriorates

Engineering Contradiction:

ImprovestrengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent uses a composite structure combining aluminum facing material with wooden framing elements. The aluminum provides strength and durability while the wood provides structural support, creating a composite panel that achieves high strength-to-weight ratio and rust resistance simultaneously

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If aluminum is used for formwork facing, then weight is reduced and ease of fastening is improved, but durability deteriorates and reactivity with cement paste increases

Engineering Contradiction:

ImproveweightVSAvoiddurability

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent combines aluminum facing with wooden framing to create a composite panel where each material compensates for the other's weaknesses. The wood provides durability and structural integrity while the aluminum maintains light weight and fastening ease

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The wooden framing acts as an intermediary between the aluminum facing and the cement paste, preventing direct contact and thus preventing the harmful chemical reaction between aluminum and cement paste

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If plywood is used for formwork facing, then replaceability and stiffness are improved, but water resistance deteriorates and durability deteriorates

Engineering Contradiction:

ImprovereplaceabilityVSAvoidwater intrusion

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent uses aluminum facing material that acts as a flexible yet protective shell, providing water resistance and durability while maintaining the replaceable nature of the panel system

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The composite construction of aluminum facing combined with wooden framing creates a panel that is both water-resistant and durable, while remaining replaceable as a complete unit

Inventive Principle:

Principle #40Composite materials

4Strength

If composite plastic facing is used, then durability is improved and water resistance is improved, but weight increases and cost increases

Engineering Contradiction:

ImprovedurabilityVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent creates a composite panel using aluminum facing and wooden framing that achieves durability and water resistance comparable to composite plastic, but with significantly lower weight and cost

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material parameters by selecting aluminum and wood combinations that provide equivalent performance to composite plastic in terms of durability and water resistance, but with different weight and cost characteristics

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The panel provides extreme durability, resistance to water and impacts, is lightweight, cost-effective, and repairable, surpassing the performance of steel and plywood while being more economical than composite plastics.

Implementation Method 1

a honeycomb core between the first polymer sheet and the second polymer sheet

Methodology Applied

Scientific EffectHoneycomb structure:

Implementation Method 2

the first uni-directional continuous fiber reinforced sheet and second uni-directional continuous fiber reinforced sheet are thermally bonded to the honeycomb core

Methodology Applied

Scientific EffectThermal bonding:

Implementation Method 3

feature a polypropylene film layer for improved durability and water resistance

Methodology Applied

Scientific EffectHydrophobic barrier: Hydrophobe

Data Source

PatentUS20250170808A1Panels for formwork and related devices, systems, and methods

Publication Date: 2025.05.29 WILIAN HOLDING CO

AI summary

A facing panel comprising a first polymer sheet, a second polymer sheet, and a honeycomb core between the first polymer sheet and the second polymer sheet. A method for forming a facing panel comprising feeding a first polymer sheet, a second polymer sheet, and a honeycomb core through a double belt press, wherein the honeycomb core is thermally bonded between the first polymer sheet and the second polymer sheet.