Prefabricated Wall Element Stability via Segmented Formwork
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Solution Overview
Problem
Existing prefabricated composite wall elements lack sufficient flexural rigidity and stability, and the production process is inefficient, particularly in terms of material usage and assembly time.
Innovation Solution
The use of formwork blocks with specific cavity and through-opening configurations for grouting material, combined with a method of stacking and bonding that includes a ½ bond and offset arrangement, along with the use of plate-shaped support structures for enhanced stability and material bonding, reduces the need for additional connection profiles and improves handling and transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If formwork blocks are stacked with ½ bond and offset arrangement, then stability is improved, but manufacturing complexity increases
Solution Approach 1:
The wall element is divided into multiple formwork blocks stacked in rows with ½ bond arrangement, where each block is a separate unit that can be manufactured independently and then assembled, improving stability through the segmented structure while allowing standardized production
Solution Approach 2:
The formwork blocks are designed with asymmetric features including offset arrangements and specifically shaped end faces (with denominators and segments) that create a stable interlocking pattern when stacked, enhancing structural stability through asymmetric geometry
2Productivity
If through-openings are provided in formwork blocks for grouting, then filling efficiency is improved, but device complexity increases
Solution Approach 1:
Through-openings are pre-formed in the formwork blocks during manufacturing, allowing grouting material to be injected through adjacent blocks without requiring additional drilling or opening operations during assembly, thus improving filling efficiency while the openings are created in the standard production process
Solution Approach 2:
The formwork blocks serve multiple functions: they provide structural support, contain cavities for reinforcement, and include through-openings that enable grouting material to flow through adjacent blocks, allowing a single component to perform multiple functions without requiring separate specialized elements
3Strength
If connection profiles are used to increase flexural rigidity, then strength is improved, but device complexity increases
Solution Approach 1:
The function of connection profiles for increasing flexural rigidity is merged into the formwork blocks themselves through the ½ bond stacking arrangement and offset patterns, where the blocks interlock to provide rigidity without requiring separate connection elements, thus combining structural support and rigidity functions into the primary components
4Reliability
If end faces are kept closed during transport, then reliability is improved, but ease of operation worsens
Solution Approach 1:
End faces are pre-closed during manufacturing to maintain reliability during transport and storage, preventing contamination or damage, while the design allows for easy opening of specific end faces at the construction site through the through-openings and grouting process when operational access is needed
Data Source
Figure 1~2
Figure 3A~5C
Figure 6A~4C(c)
AI summary
A prefabricated house wall element according to the invention comprises formwork blocks (10; 20; 30; 40; 50) arranged in rows, in particular in one piece, which have cavities and through-openings (12, 14, 15; 22, 24, 25; 52, 54, 55) for at least partially filling formwork blocks with grout material, in particular concrete, by adjacent formwork blocks, wherein at least one first closing formwork block (10) has at least one closed end face (11) in the longitudinal direction of the row, which adjoins a formwork block above it, in particular another closing formwork block (20), and/or first broad sides of the formwork blocks (10; 20; 30; 40; 50), in particular over at least 50% of their surface, are bonded to a first plate-shaped support structure (1) and opposite second broad sides of the formwork blocks (10; 20; 30; 40;50), in particular on at least 50% of their surface, are bonded to a second plate-shaped support structure (2).