Textile-Reinforced Concrete Formwork Panel for Surface Quality and Reuse
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Solution Overview
Problem
Existing concrete formwork technologies face challenges in ease of use, limited reusability, and difficulty in producing high-quality, patterned or smooth concrete surfaces, often resulting in damage to the formwork and concrete surfaces during removal.
Innovation Solution
A concrete formwork panel featuring a wood-based carrier with a textile fabric reinforced by a B-stage capable binder, providing a three-dimensional structure and improved water drainage, allowing for the production of both smooth and patterned surfaces, and enabling frequent reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional wooden board panels are used as formwork, then the concrete takes on the appearance of the wooden board grain, but the formwork can only be reused to a limited extent and may damage the concrete surface during removal
Solution Approach 1:
The formwork panel uses a composite structure combining a wood-based carrier with a textile fabric layer reinforced by a B-stage capable binder. This composite material provides both the structural integrity needed for reuse and the surface quality needed for high-finish concrete surfaces, resolving the contradiction between reusability and surface quality.
Solution Approach 2:
The patent applies a B-stage capable binder that can be partially cured to provide initial strength while remaining flexible enough to allow formwork removal without damaging the concrete surface. The binder's curing parameters are controlled to achieve optimal balance between formwork rigidity and surface release, enabling repeated use without surface damage.
2Ease of operation
If fabric is bound to the carrier and made immovable, then drainage of water from curing concrete is improved, but fine concrete particles fill the pores of the fabric and make detachment difficult or impossible
Solution Approach 1:
The B-stage capable binder is partially cured to maintain a degree of flexibility in the textile fabric while providing sufficient structural support for drainage. This partial curing state allows the fabric to remain permeable to water while preventing fine concrete particles from completely filling the pores, and enables easier detachment after concrete hardening.
3Reliability
If the concrete formwork is designed for high reusability, then the number of reuse cycles increases, but the complexity of the formwork structure increases
Solution Approach 1:
The wood-based carrier combined with the textile fabric and B-stage binder creates a composite material that inherently provides high reusability. The wood-based carrier offers structural strength and stability for multiple reuse cycles, while the textile fabric layer provides surface quality and drainage functionality, achieving high reusability without excessive structural complexity.
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 solution enables the production of high-quality concrete surfaces with enhanced durability and ease of formwork handling, allowing for more frequent reuse and improved mechanical resistance, while maintaining the ability to produce both smooth and patterned surfaces effectively.
Implementation Method 1
at least one textile fabric applied to at least one of the two sides of the backing and which has been reinforced with at least one B-stage capable binder
Implementation Method 2
the surface of the textile fabric has a three-dimensional structure
Data Source
AI summary
The panel has a textile sheet material e.g. mineral non-woven fabric fleece, evenly applied on a side of a carrier e.g. oriented strand board, and hardened using a B-stage compatible binder. Function materials are applied on an upper side of the hardened textile sheet material. A surface weight of the sheet material ranges between 15 and 500 g per meter square. A surface of the sheet material includes three-dimensional structures in form of grooves and/or knots. An auxiliary barrier layer is formed between the carrier and the sheet material. An independent claim is also included for a method for manufacturing a shuttering to manufacture a concrete mold. The textile sheet material is made of fibers of synthetic polymers, ceramic fibers, mineral fibers or glass fibers.