Modular Concrete Form Assembly with Integrated Rebar Stabilization

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Solution Overview

Problem

Existing form assemblies for concrete slabs are labor-intensive and inefficient due to the need for measuring and cutting wood segments, wear out quickly, and require multiple stakes for stability, leading to inefficiencies and high costs.

Innovation Solution

A form assembly with a predefined outer frame composed of coupled segments and a lifting apparatus, where rebar members are securely attached to maintain the frame's shape and facilitate easy assembly and transportation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If wood segments are used to form the outer frame, then the form assembly can be easily constructed, but the segments require measuring and cutting each use which is labor intensive

Engineering Contradiction:

Improveease of constructionVSAvoidtime for measuring and cutting

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The outer frame segments are pre-assembled with coupling portions and rebar members attached beforehand. This preliminary preparation eliminates the need for measuring and cutting wood segments during each use, as the segments are ready-to-use modular units that can be quickly assembled into the desired frame configuration.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The outer frame is divided into multiple separable segments that can be independently handled and assembled. Each segment includes coupling portions that enable quick connection without requiring on-site measurement or cutting, making the assembly process more efficient and reducing labor time.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If wood segments are used for the outer frame, then the frame can be assembled, but the segments wear out and must be discarded after use

Engineering Contradiction:

Improveease of assemblyVSAvoidwaste of wood segments

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The design transitions from disposable wood segments to reusable metal segments. The segments are engineered to withstand multiple uses without degradation, and the rebar members are permanently attached to the segments, eliminating the need to discard the entire assembly after one use. This recovery and reuse principle reduces material waste significantly.

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The outer frame segments combine metal construction with attached rebar members to create a composite structure that is more durable than wood alone. This composite design resists wear and degradation, allowing the segments to be reused across multiple concrete slab formations without losing structural integrity.

Inventive Principle:

Principle #40Composite materials

3Device complexity

If rebar members are not attached to the wood segments, then the assembly is simple, but the rebar members move independently within the form assembly

Engineering Contradiction:

Improvesimplicity of assemblyVSAvoidstability of rebar position

Core Design Contradiction:

Device complexityVSStability of the object's composition

Solution Approach 1:

The rebar members are permanently attached to the outer frame segments through welding or other permanent joining methods. This merging of the rebar and frame into a single integrated unit eliminates independent movement of the rebar members while maintaining the simplicity of the overall assembly process, as the attached rebar travels with the segment during assembly and placement.

Inventive Principle:

Principle #5Merging (Combining)

4Stability of the object's composition

If multiple posts or stakes are used to secure the wood segments, then the frame stays in place, but the process requires more materials and effort

Engineering Contradiction:

Improvestability of frame positionVSAvoidnumber of posts or stakes

Core Design Contradiction:

Stability of the object's compositionVSQuantity of substance

Solution Approach 1:

The design extracts the stabilization function from separate posts or stakes and integrates it into the outer frame segments themselves. The segments are designed with inherent stability features and coupling mechanisms that secure them to each other and to the ground, eliminating the need for multiple additional posts or stakes while maintaining frame stability.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS9145679B2Form assembly for concrete slabs and methods of assembling same

Publication Date: 2015.09.29 XTREME CUBES CORP

AI summary

A form assembly includes an outer frame having a predefined shape. The frame includes at least two segments that are coupled together at a coupling portion. Each segment includes a first flange and a second flange positioned a predefined distance from the first flange. The first flange includes openings that extend substantially therethrough and the second flange includes openings that extend substantially therethrough and that are substantially concentrically aligned with the first flange openings. A lifting apparatus is positioned in a location that is bounded by the frame. Rebar members are coupled to the frame such that at least a portion of one of the rebar members is positioned within one first and second flange openings. At least four rebar segments are coupled to the lifting apparatus such that the rebar segments define an X-shape within the form assembly to facilitate maintaining the frame in the predefined shape.