Plastic Fastening Bracket with Framework and Offset Nail Loops
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Solution Overview
Problem
Existing mounting brackets for slab edge shuttering made of plastic struggle to meet rigidity requirements while being cost-effective, as they either require expensive materials or additional reinforcement that increases production costs, and often allow concrete to flow between the formwork and retaining leg, leading to an imperfect surface.
Innovation Solution
A mounting bracket design featuring a framework construction between the base and holding legs with additional reinforcement elements and offset nail loops that enhance flexural rigidity and concrete flow, allowing for reduced plastic usage and adapted rigidity without increasing costs, and ensuring a smooth concrete surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If inexpensive plastic materials are used for mounting brackets, then production costs are reduced, but the rigidity and strength requirements cannot be met
Solution Approach 1:
The mounting bracket uses a composite structure combining plastic base material with integrated reinforcement elements (steel or aluminum profiles) to achieve the required rigidity and strength while keeping production costs low. The reinforcement elements are embedded within the plastic structure to form a hybrid composite system that leverages the advantages of both materials.
Solution Approach 2:
The mounting bracket is divided into functional segments: the plastic base structure providing overall form and cost-effectiveness, and separate reinforcement elements providing localized strength where needed. This segmentation allows optimization of each component for its specific function while maintaining overall cost efficiency.
2Strength
If reinforcement elements are added to increase rigidity, then strength requirements are met, but production costs increase
Solution Approach 1:
The reinforcement elements are nested within the plastic structure during the molding process, with the plastic material forming around and integrating with the reinforcement profiles. This nesting approach eliminates separate assembly steps and reduces overall production costs while achieving the required rigidity.
Solution Approach 2:
Reinforcement elements are strategically placed only in specific areas where structural strength is required, rather than uniformly throughout the entire bracket. This localized reinforcement approach minimizes material usage and production costs while meeting the necessary rigidity requirements.
3Ease of manufacture
If nail loops are positioned on top of each other, then manufacturing is simplified, but liquid concrete flows between formwork and retaining leg causing surface defects
Solution Approach 1:
The nail loops are arranged in an asymmetric staggered pattern rather than being vertically aligned. This asymmetric arrangement creates offset positions that block the vertical flow path of liquid concrete, preventing it from reaching the formwork and causing surface defects, while still maintaining manufacturing simplicity.
4Strength
If more plastic is used to increase rigidity, then strength requirements are met, but the bracket becomes heavier and production costs increase
Solution Approach 1:
The mounting bracket uses a composite structure combining plastic base material with integrated reinforcement elements (steel or aluminum profiles) to achieve the required rigidity and strength while keeping production costs low. The reinforcement elements are embedded within the plastic structure to form a hybrid composite system that leverages the advantages of both materials.
Data Source
AI summary
The fastening bracket (1) is made of plastic and comprises a base limb (3) and a retaining limb (5). The base limb (3), having a lower cover plate (11) and an upper cover plate (13), comprises a framework, which is formed by brace pairs (17) and (19), which extend between the two cover plates (11, 13) in the manner of a roof. The base limb (3) extends under the retaining limb (5) to the outer surface (23) of the retaining limb. Nail loops (9) are arranged on the retaining limb (5) in such a way that the flow of the liquid concrete is promoted between the formwork and the fastening bracket (1).