Expandable Panel Structures for Modular Construction
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Solution Overview
Problem
Conventional construction methods for multi-tiered structures are labor-intensive, inefficient, and costly due to the need for complex assembly and transportation of materials, which are often affected by weather and require precise on-site construction.
Innovation Solution
The development of expandable panel structures that can be easily manufactured and assembled into various configurations, featuring a sheet of material with patterns of cuts and apertures that allow it to transition from a flat to a stepped shape, facilitated by end plates and connectors for support and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rectangular frames and studs are assembled on-site, then structural stability is achieved, but construction time and labor costs increase significantly
Solution Approach 1:
The panel structure is pre-assembled in a factory setting with all framing, studs, and sheathing prepared in advance. This preliminary action eliminates on-site assembly of individual components, dramatically reducing construction time while maintaining structural integrity through controlled manufacturing processes.
Solution Approach 2:
Multiple separate components (frames, studs, sheathing) are merged into a single integrated panel structure. This consolidation allows the entire wall assembly to be installed as one unit, improving construction speed while the integrated design ensures structural stability is maintained.
2Quantity of substance
If conventional materials are shipped to job sites, then construction materials are available, but transportation space and number of trips increase
Solution Approach 1:
The panel structure utilizes nested configuration where sheathing is attached to the framework in a layered arrangement. This nesting allows materials to be compactly organized within the same transport space, reducing the volume required for shipping while ensuring all necessary materials are available for construction.
Solution Approach 2:
Multiple materials (wood framework, sheathing panels) are merged into a single pre-assembled unit. This consolidation reduces the number of separate shipments needed, as the entire wall structure arrives in one transport load rather than requiring multiple trips for different materials.
3Shape
If complex multi-tiered framing is assembled, then multi-story structures are achieved, but assembly complexity and time increase
Solution Approach 1:
The multi-story structure is segmented into discrete panel units that can be manufactured separately and then assembled vertically. This segmentation reduces assembly complexity by breaking down the complex multi-tiered framing into manageable modules, while the standardized connection systems maintain structural integrity across tiers.
Solution Approach 2:
Each panel tier is pre-assembled in the factory with all framing and connections prepared in advance. This preliminary action eliminates the need for complex on-site assembly operations, allowing multi-story structures to be built by simply stacking pre-prepared panels rather than assembling complex frameworks floor by floor.
4Productivity
If prefabricated panel structures are used, then construction efficiency improves, but manufacturing precision requirements increase
Solution Approach 1:
The structure is divided into standardized panel modules with uniform dimensions and connection points. This segmentation allows for repeated manufacturing processes that can achieve high precision through automation, while the modular nature maintains construction efficiency by allowing simple assembly of identical units.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces construction time and costs by allowing for modular, cost-effective assembly of multi-tiered structures with fewer materials, easier transportation, and reduced labor requirements, while maintaining structural integrity and flexibility.
Implementation Method 1
a first side segment formed in the sheet of material and having an outer leg and an inner leg configured to allow the first side segment to bow when the sheet of material moves from the nonexpanded position to the expanded position
Data Source
AI summary
A multi-tiered building structure. The multi-tiered building structure includes a panel member having a pattern of cuts, a pattern of legs, and a pattern of tabs configured to move the panel member between a nonexpanded position, wherein the panel member forms a substantially flat shape, and an expanded position, wherein the panel member forms a substantially stepped shape. The building structure also includes a support structure configured to accept at least one of the pattern of tabs of the panel member and maintain the panel member in the expanded position.