Collapsible Wall Frame with Foldable Spacers

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Solution Overview

Problem

Traditional construction methods for structural frames, such as platform framing and prefabricated systems, face challenges including high labor costs, errors due to manual measurement and marking, need for cranes, and increased transportation and storage costs, especially when building with wood or other materials.

Innovation Solution

A prefabrication system using pre-distancing collapsible frames with foldable spacers integrated into the structural components, allowing for automated production and quick on-site assembly, eliminating the need for manual measuring and cutting, and reducing transportation costs by maintaining the same volume as traditional construction materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional platform framing is used with manual measurement and marking, then flexibility in on-site construction is maintained, but labor costs increase and errors occur due to human error

Engineering Contradiction:

Improveon-site construction flexibilityVSAvoidlabor time and error correction time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-marking and pre-cutting all structural components (studs, plates, joists) at the manufacturing plant before shipping to the construction site. This eliminates the need for on-site measurement, marking, and cutting operations, thereby reducing labor time and errors while maintaining construction flexibility through pre-assembled sections.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent segments the construction process into manufacturing-phase operations (cutting, marking, notching) and on-site assembly operations. By completing the complex manufacturing tasks off-site and delivering pre-processed components or sections, the system reduces on-site labor requirements while maintaining the ability to adapt to site conditions during assembly.

Inventive Principle:

Principle #1Segmentation

2Productivity

If prefabricated walls or sections are manufactured off-site, then construction speed increases, but transportation costs and storage requirements increase

Engineering Contradiction:

Improveconstruction speedVSAvoidtransportation volume and storage space

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The patent segments the prefabrication into two levels: complete wall sections (including sheathing) for high-speed assembly, and individual structural components for projects requiring lower transportation volume. This segmentation allows clients to choose the appropriate level of prefabrication based on their specific needs for construction speed versus transportation and storage constraints.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates a universal manufacturing system that can produce both complete prefabricated walls and individual structural components using the same equipment and processes. This multi-functionality allows the system to optimize for either construction speed (complete walls) or transportation efficiency (individual components) depending on the project requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If complete walls with sheathing are prefabricated off-site, then construction time is reduced, but fixed facility costs and equipment costs increase

Engineering Contradiction:

Improveconstruction timeVSAvoidfacility and equipment requirements

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent segments the value-added operations between centralized manufacturing (cutting, marking, notching, drilling) and on-site assembly (placement, connection, finishing). By performing the complex manufacturing operations in a shared facility and delivering pre-processed components or sections, the system reduces construction time while distributing facility costs across multiple projects rather than requiring each contractor to own expensive equipment.

Inventive Principle:

Principle #1Segmentation

4Volume of moving object

If collapsible light metal frames are used, then transportation efficiency improves, but production cost increases due to additional industrial processes

Engineering Contradiction:

Improvetransportation volumeVSAvoidproduction cost

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

Instead of collapsing the frame for transportation as in conventional systems, the patent inverts the approach by shipping the frame in its expanded, ready-to-assemble configuration. The frame components are pre-cut and pre-marked in the expanded state, eliminating the need for complex collapsing mechanisms and additional industrial processes while maintaining transportation efficiency.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS11028575B2Method and system for collapsible wall frame with spacers that pre-determine placement of structural components

Publication Date: 2021.06.08 PRE FRAMING CORP

AI summary

Provided is a pre-distancing collapsible system particularly for the elements of a structural frame of a building such as a wall frame. An embodiment includes at least three components of a structural frame and at least two spacers. The spacers are not structural elements of the frame and may be fastened to heads of the structural components of the frame. The spacers may be foldable. A manufacturing method for assembling the wall frame components for shipping is provided. A method for forming a wall frame from the shipped, packed-together components is also provided.