Polymer Concrete Form with Cellular Insert for Non-Round Columns
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Solution Overview
Problem
Existing forms for pouring non-round concrete columns are complex, expensive, and lack reusability and efficient shipping options, as they often require factory assembly and are not easily assembled in the field, leading to high shipping costs and damage during use.
Innovation Solution
A concrete form comprising a pre-formed polymer liner sheet, a polymer backing sheet, and prefabricated cellular material pieces that can be assembled into an insert assembly, allowing for easy field assembly, nesting for space-efficient shipping, and reusability, with the cellular material protected by the sheets to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If polymer foam inserts are used to form non-round columns, then the desired non-round cross-section can be achieved, but the foam becomes exposed and torn or disintegrated as the insert is stripped from the column
Solution Approach 1:
The patent applies a flexible liner material (such as plastic or metal sheeting) that conforms to the non-round cross-section and can be stripped from the concrete column without tearing or disintegrating. This flexible shell protects the structural integrity of the insert during the stripping process while still allowing the desired non-round shape to be formed.
Solution Approach 2:
The patent creates a composite insert structure combining polymer foam (for rigidity and shape definition) with a flexible liner material (for easy stripping). This composite construction allows the foam to maintain the non-round cross-section while the flexible liner protects the foam from exposure and disintegration during stripping.
2Ease of operation
If inserts are pre-assembled in the factory, then the form is ready for use, but the forms are bulky and shipping costs are relatively high
Solution Approach 1:
The patent divides the insert into separate components (foam sections and liner material) that can be packaged compactly and assembled on-site. This segmentation allows the components to be shipped in a space-efficient manner while still providing a ready-to-use form when assembled, reducing shipping volume without sacrificing ease of operation.
Solution Approach 2:
The patent pre-forms the foam sections and liner material separately in the factory, preparing them for easy assembly on-site. This preliminary preparation of individual components allows for compact shipping while maintaining readiness for use, as the components can be quickly assembled into the complete insert form at the construction site.
3Shape
If wooden forms are used, then non-round columns can be formed, but the forms are relatively expensive and require substantial skill to construct
Solution Approach 1:
The patent employs a disposable or limited-use insert system made from inexpensive materials like polymer foam and simple liner material. This eliminates the need for complex, reusable wooden forms while providing the necessary non-round shape. The insert is designed to be used once or a few times and then discarded, reducing both cost and construction complexity.
Solution Approach 2:
The patent changes the material parameters from traditional wooden forms to modern polymer-based materials that are easier to manufacture and assemble. This material substitution reduces the skill level required for construction while maintaining the ability to form non-round cross-sections, effectively simplifying the overall device complexity.
4Volume of moving object
If multiple insert assemblies are nested for shipping, then space efficiency is improved, but the assembly must be robust enough to withstand nesting and handling
Solution Approach 1:
The patent designs the insert assemblies to be nestable within one another, allowing multiple forms to be shipped in a compact configuration. The liner material and foam structure are engineered to provide sufficient strength and protection during nesting and handling, preventing damage while maximizing space efficiency in shipping containers.
Data Source
AI summary
A concrete form comprises a single insert assembly or a plurality of insert assemblies within an outer tube. Each insert assembly comprises a pre-formed polymer liner sheet, a pre-formed polymer backing sheet, and a plurality of prefabricated cellular material pieces. Each cellular material piece has a first surface configured to form a portion of the non-round cross-section desired for the column and an opposite second surface formed substantially as an angular section of a cylinder. An insert assembly is constructed by affixing the liner sheet to the first surfaces of a plurality of the cellular material pieces. The cellular material pieces are arranged in a plurality of laterally adjacent rows extending lengthwise along the liner sheet for a length approximately equal to the length of the outer tube. The backing sheet is then fixed to the second surfaces of the cellular material pieces. The liner sheet and backing sheet together substantially fully envelope the cellular material pieces.