Reusable Laminate Formwork for Adjustable Concrete Columns

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Solution Overview

Problem

Current construction methods for building circular columns are inefficient due to the limitations of non-adjustable, bulky, and non-reusable Sonotube concrete forms, which are expensive, time-consuming, and require large storage spaces, and cannot accommodate columns of non-standard diameters or shapes.

Innovation Solution

The use of flexible, durable, and pre-curled laminate sheets made from materials like PileMedic PLG60.60 or other plastics, which can be easily wrapped around cores to form adjustable diameter columns, allowing for easy installation, reuse, and adaptation to various shapes and sizes without the need for additional framing or adhesives.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If Sonotube concrete forms are used, then circular columns can be constructed, but the forms are non-adjustable and cannot accommodate columns of nonstandard diameters or shapes

Engineering Contradiction:

Improveadaptability to different column diameters and shapesVSAvoidformwork system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The formwork system transitions from rigid, fixed-size Sonotubes to dynamic, adjustable configurations using flexible laminate sheets that can be wrapped around cores of various diameters and shapes, allowing the formwork to adapt its geometry rather than forcing the structure to fit a fixed form

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent replaces rigid tubular forms with flexible laminate sheets that can be conformally wrapped around different geometric configurations, enabling the same basic material to serve multiple column types through flexible deformation rather than requiring multiple specialized forms

Inventive Principle:

Principle #30Flexible shells and thin films

2Ease of manufacture

If Sonotube concrete forms are used, then columns can be constructed, but the forms are bulky and require large storage spaces

Engineering Contradiction:

Improveease of constructionVSAvoidstorage volume required

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

The invention extracts the essential forming function from the bulky Sonotube structure itself, separating the formwork material (laminate sheets) from the supporting core structure, allowing the sheets to be stored compactly and deployed only when needed around the actual column core

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The formwork is transformed from three-dimensional rigid tubes to two-dimensional flexible sheets that can be rolled or folded into compact storage configurations, reducing the storage volume dramatically while maintaining the ability to form three-dimensional column shapes during construction

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Productivity

If Sonotube concrete forms are used, then columns can be constructed, but the forms are non-reusable and expensive

Engineering Contradiction:

Improveconstruction efficiencyVSAvoidmaterial waste

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The laminate sheets are designed to be removed cleanly from the cured concrete column surface and reused in subsequent construction projects, recovering the material value and eliminating waste, whereas Sonotubes are discarded after single use requiring replacement for each column

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The same laminate sheet material can serve multiple functions across different projects and column types, providing universal applicability that replaces the need for dedicated single-use forms for each column, thereby improving productivity through material reuse

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Ease of operation

If Sonotube concrete forms are used, then circular columns can be formed, but additional framing or adhesives are required

Engineering Contradiction:

Improveease of installationVSAvoidadditional components required

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The laminate sheets are designed to self-constrain during concrete pouring through their inherent flexibility and friction against the wet concrete, eliminating the need for external framing structures or adhesive bonds to maintain form integrity, thereby simplifying installation

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS11591810B2Reusable and adjustable-size form for repair and reinforcement of structures

Publication Date: 2023.02.28 EHSANI MOHAMMAD R

AI summary

A method and an article of manufacture are disclosed for constructing, reinforcing, and repairing various structural elements such as columns, piles and the like using formworks that are reusable. The reusable articles of manufacture employed in the disclosed methods are or, if desired, may be permanently left in place. Same or similar methods and articles of manufacture may be employed to easily construct pipes of any desired diameter in a very short time.