Double-Shell Modular Structure for Lightweight Load-Bearing

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Solution Overview

Problem

Existing building structures with double-shell area-covering modules are heavy and lack interaction between spaced surface elements for optimal load-bearing effects, limiting their efficiency and versatility in various geometries and construction methods.

Innovation Solution

A double-shell area-covering structure module composed of upper and lower secondary shell elements connected by crossbars and diagonal rods, forming a primary shell support structure with a truss effect, allowing for easy assembly and adaptation in different geometries and construction methods, with adjustable spacing and materials for enhanced load capacity and flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional heavy building structures are used, then load-bearing capacity is sufficient, but weight is excessive and assembly complexity increases

Engineering Contradiction:

Improveload-bearing capacityVSAvoidstructure weight

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The structure is divided into modular elements (nodes and bars) that can be assembled in different configurations. Each module contains integrated connection pockets and mounting elements, allowing standardized assembly while maintaining structural integrity through the modular truss effect

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention combines different materials (metal profiles, plastic elements, wood) within single modules to optimize the strength-to-weight ratio. Connection pockets, bars, and nodes use material combinations that provide sufficient load-bearing capacity while minimizing overall structure weight

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If fixed-geometry structures are used, then structural stability is maintained, but adaptability to different geometries and construction methods is limited

Engineering Contradiction:

Improvestructural stabilityVSAvoidgeometric adaptability

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The modular design allows the structure to be dynamically reconfigured for different geometries. Modules can be assembled in various patterns (rectangular, triangular, curved) while maintaining structural stability through the truss effect, enabling adaptation to different building requirements

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The standardized modules with universal connection pockets and mounting elements can be used across multiple geometry types and construction methods. The same basic module serves different functions depending on its arrangement and configuration, providing both stability and versatility

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If complex connection solutions are used, then structural integrity is ensured, but ease of assembly and industrial prefabrication is reduced

Engineering Contradiction:

Improvestructural integrityVSAvoidease of assembly

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Connection functionality is segmented into integrated components (pockets, mounting elements, bars) that are pre-assembled within modules during industrial manufacturing. This reduces on-site assembly complexity while maintaining structural integrity through standardized connection mechanisms

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Modules contain self-contained connection elements (pockets with mounting elements) that enable automatic or tool-free assembly. The integrated design allows structures to be assembled by simply connecting modules together, reducing the need for complex connection procedures while ensuring structural integrity

Inventive Principle:

Principle #25Self-service

4Ease of manufacture

If spaced surface elements are used without interaction, then manufacturing simplicity is maintained, but load-bearing efficiency is suboptimal

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidload-bearing efficiency

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The invention merges spaced surface elements (upper and lower shells) into an integrated double-shell structure with interactive components. Crossbars and diagonal rods connect the shells, creating a truss effect that enhances load-bearing efficiency while maintaining manufacturing simplicity through standardized module assembly

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11339562B2Area-covering structure module

Publication Date: 2022.05.24 HEIDENREICH BERND

AI summary

A double-shelled load-bearing structure module of any geometric shape, is formed from top and bottom secondary shell elements. A double-shelled load-bearing structure in the form of a primary shell structure is joined with the module, made of individual assembled load-bearing structure modules of this kind having statically necessary filling rods. The secondary shell elements have, in each corner, a connection pocket, which is open at the top or bottom or is open at the top and bottom, of appropriate size for connecting a plurality of load-bearing structure modules. The connection pocket, at least on the outside, on the outer vertical surfaces of the secondary shell elements, is delimited by preferably metal profiles or metal sheet. Connection tabs can also be disposed in each corner instead of connection pockets. The connection tabs are formed from angular surfaces, preferably metal sheet, protruding towards the intermediate space between the secondary shell elements.