Interlocking Modular Substructures for Aligned Insulated Concrete Walls

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Solution Overview

Problem

Conventional insulated concrete wall forms are unstable, require manual alignment, lack structural strength, and often necessitate additional framing, leading to inefficiencies in precision and cost.

Innovation Solution

Modular framework substructures with exterior and interior panels, interlocking features, and channels for insulation and rebar support, allowing for precise and cost-effective construction of insulated concrete walls.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional insulated concrete wall forms are used, then the wall insulation function is achieved, but the forms are unstable and require additional framing for structural strength

Engineering Contradiction:

Improvestructural strengthVSAvoidadditional framing

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The wall form is divided into modular panels that can be assembled in different configurations. Each panel is a self-contained unit with integrated insulation and framing elements, allowing the structure to achieve structural strength through modular assembly rather than requiring separate additional framing components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention combines the insulation panels, structural framing, and wall form into a single integrated modular unit. This merging of functions eliminates the need for separate additional framing while maintaining both insulation performance and structural strength, as the modular panel itself provides the necessary structural support.

Inventive Principle:

Principle #5Merging (Combining)

2Manufacturing precision

If manual alignment of forms is used, then installation is flexible, but alignment precision is difficult to execute with high level of precision

Engineering Contradiction:

Improvealignment precisionVSAvoidmanual alignment

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The modular panels incorporate localized alignment features such as tapered edges, guide rails, or interlocking geometries at specific contact points. These localized features provide precise alignment guidance without requiring complex overall alignment mechanisms, maintaining ease of manual assembly while achieving high precision.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The modular panels are designed with self-aligning features that automatically guide proper positioning during assembly. The tapered edges or geometric interlocking mechanisms cause the panels to self-align as they are brought together, eliminating the need for manual measurement and adjustment while ensuring precise alignment.

Inventive Principle:

Principle #25Self-service

3Stability of the object's composition

If conventional wall forms are used, then basic wall construction is achieved, but the forms are unstable when stacked

Engineering Contradiction:

Improveform stabilityVSAvoidstacking efficiency

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The modular panels are designed with nested stacking configurations where upper panels fit into or upon lower panels through interlocking features. This nesting arrangement distributes loads effectively and prevents lateral shifting, ensuring stability when stacked while maintaining efficient assembly and disassembly for high productivity.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Strength

If conventional forms with limited structural strength are used, then insulation function is achieved, but outer surfaces cannot support siding without intermediate framing

Engineering Contradiction:

Improvesurface structural strengthVSAvoidintermediate framing

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The modular panel design merges the insulation core with an integrated structural skin or cladding attachment system. This integration provides sufficient surface structural strength directly on the panel to support siding materials, eliminating the need for separate intermediate framing while maintaining the insulation function.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20250237057A1Modular framework substructures for creating insulated concrete walls and related walls, systems, and methods

Publication Date: 2025.07.24 NGUYEN TUYEN

AI summary

Modular framework substructures for creating insulated concrete walls are disclosed, along with related systems and methods. Each substructure includes exterior panels defining, at least in part, a partial enclosure. Interior panel(s) extend between the exterior panels. An interior passageway is defined by the interior panels and the exterior panels. Additional passageway(s) are defined by the interior panels and at least one of the exterior panels and are open to an exterior. Insulating material is deposited within each of the additional passageway(s). The substructures are positioned adjacent to one another to create form(s), each of having a common fluid passageway comprising the interior passageways of the substructures of the respective form. Concrete is deposited within the common interior passageway of each of the one or more forms.