Multi-Container Interlock Frame for Weld-Free Modular Housing
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Solution Overview
Problem
Current modular housing systems require significant manual labor and specialized tools for cutting and welding shipping containers, leading to high production costs and inefficiencies, as well as the need for reinforcement to withstand extreme weather conditions.
Innovation Solution
A modular multi-container housing structure that uses a connector frame with vertical and horizontal struts and interlocks to securely connect shipping containers without cutting or welding, allowing for field assembly with handheld power tools and providing a weather-tight seal capable of withstanding hurricane winds up to 300 mph.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If containers are connected using cutting and welding methods, then structural strength is improved, but manufacturing complexity and production cost increase
Solution Approach 1:
The connector is divided into modular components including a frame structure, interlocking elements, and sealing components that can be manufactured separately and assembled together, simplifying the manufacturing process while maintaining structural integrity
Solution Approach 2:
A specialized connector acts as an intermediary component between containers, providing the connection function without requiring direct welding or cutting of the container structures themselves, thus reducing manufacturing complexity
2Strength
If containers are cut and welded together, then connection strength is improved, but production time and labor cost increase
Solution Approach 1:
The connector components are pre-manufactured and pre-assembled in a factory setting with precise tolerances, allowing for rapid field assembly without requiring time-consuming cutting and welding operations on-site
Solution Approach 2:
The mechanical connection system replaces the thermal welding process, using interlocking mechanical elements and fasteners that can be installed quickly with simple tools, dramatically reducing assembly time and labor requirements
3Reliability
If containers are reinforced to withstand extreme weather, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The connector utilizes composite construction combining corrosion-resistant metals, sealing materials, and reinforcing elements in a integrated design that provides hurricane-resistant strength without requiring separate reinforcement components on the containers themselves
Solution Approach 2:
Multiple functions are merged into the connector including structural connection, weather sealing, and reinforcement, eliminating the need for separate reinforcement components and simplifying the overall system while maintaining reliability
4Reliability
If manual fasteners and welding are used for container connection, then connection reliability is improved, but ease of manufacture deteriorates
Solution Approach 1:
The connector incorporates self-aligning and self-securing features where the interlocking elements automatically guide and secure the connection, reducing the need for precise manual alignment and complex fastening procedures while maintaining reliable connections
Data Source
AI summary
A modular multi-container housing structure connector for containers, which each have sides including a roof, a floor, and four lateral sides, includes a connector frame comprising vertical and horizontal struts shaped to connect to at least one of the sides of two adjacent containers and at least one interlock configured to secure the connector frame to the side of one container. The at least one interlock may be a plurality of interlocks. The connector frame may comprise two vertical struts and two horizontal struts each shaped and configured to connect to a respective edge of an adjacent side of two adjacent containers and, responsive to the connector frame being connected to two adjacent sides of two adjacent containers by the plurality of interlocks, the connector frame and interlocks form a container-to-connector frame-to-container connection to establish a weather-tight housing structure with the two or multiple connected containers.