Textile-Reinforced Module Connection for Freeform Concrete Shapes

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Solution Overview

Problem

Existing methods are unable to produce textile reinforcements and textile-reinforced structural modules in freeform shapes, as they lack the capability to form and integrate textile reinforcements within formwork tables, particularly for doubly curved or complex geometries.

Innovation Solution

A device and method that utilizes a forming device with a freely formable forming layer, yarn holding devices, and flexible frame strips to create textile reinforcements, which can be integrated with a curable material like concrete, allowing for the formation of complex shapes through a controlled forming process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If traditional formwork tables with rigid grating substructures are used, then structural support is provided, but freeform shape formation is impossible

Engineering Contradiction:
Improvefreeform shapeVSAvoidshape adaptability
Core Design Contradiction:
ShapeVSAdaptability or versatility

Solution Approach 1:

The patent applies the dynamics principle by replacing the rigid, fixed grating substructure with a dynamic, adjustable system. The forming table includes movable and deformable elements that can be repositioned and reconfigured to create various freeform shapes. The substructure allows for continuous adjustment during the forming process, enabling the production of complex doubly curved surfaces and freeform geometries that were previously impossible with static formwork.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent implements parameter changes by modifying the physical state and geometric parameters of the forming table components. The substructure elements can change their spatial arrangement, angle, and position to adapt to different freeform shape requirements. This dynamic parameter adjustment allows the same forming table to produce multiple different freeform geometries, resolving the contradiction between structural support and shape adaptability.

Inventive Principle:
Principle #35Parameter changes

2Strength

If textile reinforcement is laid under mechanical tension in a base frame, then tensile strength is achieved, but curved or freeform component production is impossible

Engineering Contradiction:
Improvetensile strengthVSAvoidfreeform capability
Core Design Contradiction:
StrengthVSShape

Solution Approach 1:

The patent applies dynamics by enabling the base frame and forming table to transition from a rigid, flat configuration to a deformable, curved configuration. The system allows the textile reinforcement to maintain tensile strength while the supporting structure dynamically adapts to freeform shapes during the forming process, enabling both strength and shape complexity.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent implements dimensionality change by transitioning the forming process from a two-dimensional flat base frame to a three-dimensional freeform structure. The base frame can be deformed and reconfigured in multiple spatial dimensions, allowing the textile reinforcement to conform to complex curved surfaces while maintaining its tensile properties throughout the transformation.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

3Productivity

If multiple components are joined after production, then larger structures are formed, but integration of reinforcement within formwork is lost

Engineering Contradiction:
Improveintegration efficiencyVSAvoidformwork complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The patent applies the merging principle by integrating the reinforcement laying function directly into the formwork table system. The forming table and base frame are designed to accommodate textile reinforcement placement and forming operations within the same integrated structure, eliminating the need for separate reinforcement laying equipment and subsequent component joining operations.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The patent implements multi-functionality by designing the forming table and base frame to perform multiple functions simultaneously: providing structural support, enabling freeform shape formation, and facilitating textile reinforcement integration. This universal system consolidates what would otherwise require separate specialized equipment, improving productivity while managing complexity through functional integration.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Data Source

PatentEP4022141B1Device and method for connecting textile-reinforced structural modules
Publication Date: 2025.12.17 GARIBALDI MARIA PATRICIA
  • EP4022141B1 patent drawingFigure 1~2
  • EP4022141B1 patent drawingFigure 3~5b
  • EP4022141B1 patent drawingFigure 6~10

AI summary

The invention relates to a system for connecting textile-reinforced structural modules along a connecting edge (76), which has a peripheral groove (74) having yarn loops (4). According to the invention, the system comprises a wedge element (410) and two shell elements (420) having a keyway (422) and is intended for insertion into the two peripheral grooves (74) with the overlapping yarn loops (4), wherein, furthermore, the wedge element (410) is intended to be partially extracted from the two keyways (422), which are arranged opposite one another, such that the shell elements (420) are spread apart by means of a wedge effect and the yarn loops (4) can be pulled together. The invention also relates to an apparatus and to a method for producing a textile reinforcement (10), comprising a yarn (2) arranged within a main frame (100), or for producing a textile-reinforced structural module (72), comprising the textile reinforcement (10) and a curable material, wherein a freely shapeable shaping device (200) is provided, on which the structural module is formed. According to the invention, the textile reinforcement (10) can be formed between yarn-holding devices (130, 180), which can be arranged on flexible frame strips (110). The invention also relates to a concrete component consisting of connected concrete structural modules, and to a printer file and a yarn deposition file.