Reusable Concrete Formwork Panel with Thermoset Coating
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Solution Overview
Problem
Existing concrete formwork panels, particularly those made of particleboard or oriented strand board (OSB), are either too expensive and limited to single use or prone to swelling and demolding issues, making them unsuitable for exposed concrete applications.
Innovation Solution
A method involving a two-component, water-based coating composition is applied to OSB or particleboard using a hot press to create a reusable concrete formwork panel, comprising a thermosetting resin and a release agent, ensuring easy demolding and multiple uses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If inexpensive uncoated particleboard or OSB is used for formwork panels, then production cost is reduced, but the panels swell during use and create uneven surfaces, preventing reuse
Solution Approach 1:
The patent applies a composite coating system consisting of multiple layers (primer layer, intermediate layer, and top layer) on particleboard or OSB substrates. This composite structure combines the cost advantage of particleboard with the protective and surface-quality benefits of multiple coating layers, enabling both economical production and multiple reusable cycles without swelling or surface defects
Solution Approach 2:
The patent modifies the physical and chemical parameters of the particleboard surface through sequential coating applications and controlled drying/curing processes. By adjusting coating composition, application thickness, and drying conditions, the panels achieve dimensional stability and surface uniformity suitable for exposed concrete, transforming the initially unsuitable particleboard surface into a reusable formwork surface
2Reliability
If high-quality coated plywood or solid wood panels are used for long-term reuse, then durability and surface quality are improved, but the panels cannot be cut to required sizes and lack customizability
Solution Approach 1:
The patent uses composite materials (particleboard/OSB with multi-layer coating) that combine the advantages of engineered wood products (ease of cutting and customization) with the protective qualities of coated surfaces. The coating system provides the durability needed for long-term reuse while the particleboard substrate maintains adaptability for custom sizing and design modifications
3Ease of manufacture
If uncoated particleboard or OSB is used for single-use formwork, then production cost is reduced, but demolding problems and damage occur, preventing any reuse
Solution Approach 1:
The patent changes the surface parameters of particleboard/OSB through controlled coating application and drying processes. The coating layers create a controlled-release interface between the formwork and concrete, allowing easy demolding while maintaining panel integrity for reuse, thus transforming the initially problematic uncoated surface into an operationally efficient reusable surface
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The coated panels enable cost-effective, reusable formwork suitable for exposed concrete, maintaining surface quality and allowing multiple uses without damage, with the coating ensuring easy separation from hardened concrete.
Implementation Method 1
one component of the coating composition is essentially a thermosetting resin... the applied coating composition is cured in a hot press under increased pressure and/or temperature to form a continuous coating
Implementation Method 2
the second component is a release agent... ensures good separation of the concrete formwork panel from the concrete during demolding after concrete casting
Data Source
AI summary
The invention relates to a method for producing a reusable concrete formwork panel and a concrete formwork panel for multiple use in concrete casting. In order to provide a method for producing a concrete formwork panel and a concrete formwork panel that enable multiple use and particularly cost-effective production, wherein the concrete formwork panels are also suitable for casting exposed concrete, it is provided that a chipboard or a coarse chipboard having two cover sides and side surfaces is first provided, followed by the application of a two-component, water-based coating composition by a liquid process to at least one of the cover sides, wherein one component of the coating composition has a thermosetting carrier resin and the second component comprises at least one release agent component.Finally, the applied coating composition is cured in a hot press to form a closed coating on the chipboard or on the coarse particle board.