Insulating Wall Beam with Rigid Plate Base
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Solution Overview
Problem
Existing insulating wall joists with integrated formwork suffer from deformation during handling and storage, leading to defects in flatness and increased manufacturing complexity and cost, along with prolonged hardening times due to the need for multiple steps and specialized equipment.
Innovation Solution
The introduction of a rigid plate base with embedded feet that maintain parallelism between concrete and insulating walls, allowing for efficient assembly and finishing, using existing tools, and enabling the insulating wall to be oriented externally with simplified finishes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If metal wire beams with zigzag connections are used to connect concrete wall and insulating wall, then the beam can be flexible during assembly, but the beam undergoes deformation during handling, storage and transport
Solution Approach 1:
The beam is divided into two separate components: a rigid base plate that maintains structural stability and prevents deformation, and flexible battens that provide assembly flexibility. The rigid base plate replaces the deforming metal wire structure, while the battens are separately attached to provide the needed flexibility during assembly without compromising overall beam stability.
2Adaptability or versatility
If traditional manufacturing process with wooden battens and multiple materials is used, then the insulating wall can be assembled, but the process becomes long, tedious and increases manufacturing cost
Solution Approach 1:
The invention merges multiple separate components (base plate, battens, insulating material) into an integrated assembly where the rigid base plate serves as both the structural support and the mounting surface for battens. This consolidation eliminates the need for separate attachment steps and reduces the number of different materials required, thereby streamlining the manufacturing process and improving productivity.
Solution Approach 2:
The battens are pre-attached to the rigid base plate during manufacturing, forming a pre-assembled unit. This preliminary action eliminates the need for on-site assembly of separate components, reducing manufacturing steps and increasing production efficiency.
3Reliability
If grooves are machined in insulating wall and concrete is poured for hardening, then the insulating wall can be securely connected, but the manufacturing time is doubled due to successive hardening requirements
Solution Approach 1:
The invention extracts the time-consuming groove machining and concrete pouring steps from the manufacturing process. Instead of machining grooves in the insulating wall and pouring concrete that requires hardening, the system uses a rigid base plate with pre-attached battens that provide secure connection through mechanical attachment alone, eliminating the need for successive concrete hardening cycles.
Data Source
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Figure 5
AI summary
The invention relates to a beam (5) for an insulated wall with integrated formwork, this beam (5) comprising, on the one hand, a base (6) for receiving an insulating panel of the insulating wall, made of an insulating material, and, on the other hand, feet (7) extending from the base (6) and having free ends (70) extending in a plane, intended to be embedded in another wall of the insulating wall made of concrete. This beam (5) is characterized in that the base (6) comprises a rigid plate (60) having a flat surface (61) for receiving the insulating panel, extending in a plane parallel to the plane in which the free ends (70) of the feet (7) extend, and that the beam (5) comprises means for maintaining these planes at a predetermined distance from each other. The invention also relates to an insulating wall with integrated formwork comprising a plurality of these beams (5).The invention also relates to a method for manufacturing such an insulating wall with integrated formwork.