Segmented Reinforcement Bars for Foamed Concrete Casting

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Solution Overview

Problem

The existing process for producing foamed or cellular concrete bodies with metallic reinforcement systems is inefficient due to manual suspension and attachment of supporting bars, limited positional variability, and additional processing steps for rust-proofing, leading to time and cost disadvantages.

Innovation Solution

An automated process using supporting bars with a predetermined breaking point and notches, welded to reinforcement mesh, and an aligning positioning device for precise and stable reinforcement placement, allowing for easy detachment and elimination of manual suspension and paraffin dipping steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual suspension and attachment of supporting bars is used, then reinforcement positioning can be achieved, but the process is inefficient and time-consuming

Engineering Contradiction:

Improveproduction efficiencyVSAvoidprocessing time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The supporting bar is divided into two functional parts: a lower integration portion that is welded to the reinforcement mesh and an upper suspension portion that extends into the casting mold. This segmentation allows the lower part to remain permanently attached to the reinforcement while the upper part can be easily removed after casting, thereby streamlining the process and reducing post-processing time

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The supporting bars are pre-welded to the reinforcement mesh before the casting process. This preliminary action eliminates the need for manual attachment during production, significantly improving efficiency and reducing processing time while ensuring secure positioning

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If supporting bars are suspended through drill-holes in reinforcement support beams, then reinforcement positioning is possible, but the position variability is limited

Engineering Contradiction:

Improveposition variabilityVSAvoidsupport frame structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The supporting bar is extracted from the complex support frame system and directly welded to the reinforcement mesh. This eliminates the need for drill-holes in reinforcement support beams and allows flexible positioning without being constrained by pre-drilled hole locations, thereby increasing position variability while simplifying the overall structure

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of inserting supporting bars into pre-drilled holes in the support frame, the invention inverts the approach by welding supporting bars directly to the reinforcement mesh and suspending them into the mold. This reversal provides greater positioning flexibility and reduces device complexity

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of manufacture

If paraffin dipping is performed on supporting bars, then rust-proofing agent adherence is prevented, but additional processing steps are required

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidnumber of processing steps

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The upper suspension portion of the supporting bar is designed as a temporary, disposable element that serves its purpose during casting and is then removed. Since it is not permanently embedded in the concrete, there is no need for rust-proofing treatment or paraffin dipping, eliminating this additional processing step and simplifying manufacturing

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The rust-proofing requirement is extracted from the supporting bar by removing the portion that would need protection (the upper suspension part). Only the lower integration portion remains, which is embedded in concrete and does not require rust-proofing, thereby eliminating the paraffin dipping step

Inventive Principle:

Principle #2Taking out (Extraction)

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 process enables accurate, stable, and variable positioning of reinforcements, reduces manual labor and processing steps, and prevents rust-proofing agent adherence on supporting bars, resulting in a more efficient and cost-effective production method.

Implementation Method 1

The upper part of the supporting bar is rotated around a longitudinal axis of the bar with the help of an automatable turning device... the supporting bar stably holds the reinforcement and cannot be vertically drawn out. If the supporting bar is turned by an angle of approximately 90°, the pins cease to surround the spring arm both from above and below

Methodology Applied

Scientific EffectTorsional stress:

Implementation Method 2

the lower part of which is designed to remain embedded in the cast concrete body after separation and removal of the upper part

Methodology Applied

Scientific EffectEmbedment:

Data Source

PatentUS8012391B2Process for the production of reinforced and cast, cellular or foamed concrete bodies and reinforcement support frame for the use in such a process

Publication Date: 2011.09.06 XELLA BAUSTOFFE

AI summary

The invention relates to a process for the production of cellular or foamed, cast concrete bodies that are reinforced with metallic reinforcements, and to a reinforcement support frame for use in the production of cellular or foamed, cast concrete bodies that are reinforced with metallic reinforcing bars.