Permanent Formwork Element for Ceiling Construction
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Solution Overview
Problem
Existing formwork elements for building ceilings are prone to tension and permanent deformation when filled with in-situ concrete, leading to inefficiencies in construction and increased on-site assembly time.
Innovation Solution
A formwork element designed as a permanent formwork system with a ceiling panel, top panel, and support arrangement that allows the top panel to remain statically effective after concrete solidification, eliminating the need for additional fastening measures and enabling the ceiling panel to function as a suspended ceiling, with integrated installation elements and optional thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional formwork elements with two bending plates are used, then the formwork can be simple in structure, but the ceiling panel experiences tension and permanent deformation when filled with in-situ concrete
Solution Approach 1:
The formwork element is divided into distinct functional components: a top plate that remains statically effective, a ceiling panel that serves as permanent formwork, and a support arrangement that transfers loads. This segmentation allows each component to be optimized for its specific function, preventing the tension and deformation issues that occur in traditional two-plate bending designs.
Solution Approach 2:
Instead of having both plates bend under load as in traditional designs, the invention inverts the approach by making the top plate statically effective and non-bending, while the ceiling panel is designed to remain stable and serve as permanent formwork. This inversion eliminates the tension and permanent deformation problems.
2Reliability
If additional fastening measures are implemented to secure the ceiling panel, then the structural integrity is improved, but the construction time and assembly complexity increase
Solution Approach 1:
The ceiling panel is designed to automatically attach to the support arrangement through its own structural features without requiring additional fastening measures. The support arrangement is configured to engage with the ceiling panel in a way that provides secure attachment as part of the assembly process itself, eliminating the need for separate fastening steps and reducing construction time.
3Strength
If the top plate is made statically effective to support in-situ concrete, then the load-bearing capacity is improved, but the material usage and cost increase
Solution Approach 1:
The top plate is designed to serve multiple functions: it provides the necessary load-bearing capacity to support in-situ concrete during pouring, and it simultaneously serves as the permanent ceiling structure after concrete solidification. This multi-functionality eliminates the need for additional materials that would otherwise be required for both formwork and final ceiling construction.
Solution Approach 2:
The invention merges the formwork function and the final ceiling structure into a single integrated component. The top plate performs both the temporary function of supporting concrete and the permanent function of being the finished ceiling, thereby reducing overall material usage and cost.
4Adaptability or versatility
If the ceiling panel is removed after concrete solidification to install a separate ceiling, then the installation flexibility is improved, but the construction process becomes more complex and time-consuming
Solution Approach 1:
The ceiling panel is designed to automatically transform into the final ceiling structure without requiring removal or additional installation steps. After the in-situ concrete solidifies, the ceiling panel remains in place and serves as the permanent ceiling, eliminating the need for separate ceiling installation processes.
Data Source
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AI summary
The invention relates to a formwork element that serves as permanent formwork for the production of a building ceiling and in which a support arrangement transfers the force of a not yet hardened cast-in-place concrete slab into a ceiling panel. The invention further relates to an associated method for producing a building ceiling.