Self-Supporting ICF Foam Panels for Foundation Construction

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Solution Overview

Problem

The labor-intensive and time-consuming process of constructing insulated concrete form (ICF) foundations, which requires temporary external bracing and multiple steps, makes it less popular for large-scale construction projects compared to traditional methods like concrete blocks or poured concrete.

Innovation Solution

The method involves erecting vertically-oriented ICF foam panels with internal brace supports and vertical panel supports to provide structural integrity during concrete pouring, reducing the need for external bracing and streamlining the construction process by allowing concrete to be poured between the panels, thus eliminating the need for extensive temporary bracing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If standard ICF techniques are used for foundation construction, then thermal resistance and mold resistance are improved, but labor intensity and construction time increase due to temporary external bracing requirements

Engineering Contradiction:

Improvethermal resistanceVSAvoidconstruction speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The invention extracts and eliminates the temporary external bracing system from the ICF construction process. The foam panels are designed with self-supporting features including vertical seam interlocking and internal reinforcement that allow them to stand independently during concrete pouring, removing the need for separate external bracing structures and significantly reducing labor requirements.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention merges the structural support function into the foam panel design itself. The panels incorporate internal bracing elements and seam interlocking mechanisms that provide the necessary support during concrete pouring, combining the formwork and support functions into a single integrated system rather than requiring separate external bracing.

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If temporary external bracing is erected for ICF foundation construction, then structural support during concrete pour is improved, but device complexity and labor requirements increase

Engineering Contradiction:

Improvestructural supportVSAvoidbracing system complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The invention removes the complex temporary external bracing system entirely. The foam panels are engineered with self-supporting capabilities through vertical seam interlocking and internal reinforcement structures that provide necessary structural support during concrete pouring without requiring additional external bracing elements.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The foam panels are designed to support themselves during the concrete pouring process. The vertical seam interlocking mechanism and internal panel reinforcement allow the panels to maintain their structural integrity and resist concrete pressure without external assistance, making the system self-sufficient.

Inventive Principle:

Principle #25Self-service

3Strength

If external bracing is assembled and disassembled for each ICF project, then support during pour is maintained, but time consumption and labor costs increase

Engineering Contradiction:

Improvesupport during pourVSAvoidtime for bracing assembly and disassembly

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The foam panels inherently provide their own support structure through self-supporting features. The vertical seam interlocking and internal reinforcement allow panels to stand and support themselves during concrete pouring, eliminating the time-consuming processes of assembling and disassembling external bracing for each project.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The self-supporting capabilities are built into the foam panel design during manufacturing. The vertical seam interlocking mechanisms and internal reinforcement structures are pre-integrated into the panels, so no additional support structures need to be assembled on-site before pouring.

Inventive Principle:

Principle #10Preliminary action

4Productivity

If standard wood forms are used for conventional poured concrete foundations, then construction speed is improved, but thermal resistance and mold resistance are reduced

Engineering Contradiction:

Improveconstruction speedVSAvoidthermal resistance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The invention uses composite foam panel structures that combine insulation material with self-supporting structural features. The foam panels provide both the formwork function needed for rapid construction and the thermal insulation properties, creating a hybrid system that delivers both speed and energy efficiency.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11761204B2Insulated concrete form construction method and system

Publication Date: 2023.09.19 INTEGRATED CONCRETE FORMING LTD

AI summary

A system and method for constructing an insulated concrete form (ICF) wall are provided. Vertically-oriented pairs of ICF foam panels of an ICF structure are erected above a footing, with vertical panel supports located along opposed vertical edges of each set of adjacent vertically-oriented panel pairs. An internal brace support, extending longitudinally along the structure, is installed between the individual panels of the panel pairs. Concrete is poured between the erected vertically-oriented ICF foam panels to complete the ICF wall.