External Modular Construction Connections for Faster Onsite Assembly

Solution Overview

Problem

The high cost and inefficiency of constructing buildings due to onsite labor-intensive tasks, especially at higher elevations, make traditional construction methods unfeasible, particularly in urban areas where land costs are high and resource use is critical.

Innovation Solution

A modular construction system using horizontal support structures, support rods, connecting nuts, and spacers that allow prefabricated modules to be secured and connected from the outside, eliminating the need for workers to enter building units during construction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional onsite construction methods are used, then workers can perform construction tasks inside building units, but labor costs and construction time increase significantly, especially at higher elevations

Engineering Contradiction:

Improveease of constructionVSAvoidconstruction efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The building is divided into modular units that are constructed separately and then assembled together. Each module is a complete, self-contained unit that can be built independently, allowing parallel construction of multiple modules to improve overall productivity while maintaining ease of construction through standardized processes

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Construction tasks are performed in advance during module fabrication rather than during onsite assembly. Electrical systems, plumbing, drywall, and other interior finishes are installed while modules are being built in controlled environments, eliminating the need for workers to enter completed building units during construction and significantly improving construction efficiency

Inventive Principle:

Principle #10Preliminary action

2Productivity

If modular construction is used to improve construction efficiency, then assembly speed increases, but the complexity of the connection mechanism increases

Engineering Contradiction:

Improveassembly speedVSAvoidconnection mechanism complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The connection mechanism uses standardized, multi-functional components such as universal support rods that can accommodate different module configurations, standardized connection plates that work with various module types, and adjustable fastening systems that handle multiple connection requirements. This universality maintains assembly speed while reducing the overall complexity by using repeated standard components rather than custom solutions for each connection type

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The connection mechanism employs nested structural elements where support rods pass through connection plates that are integrated into module frames, with additional nesting of fastening components and alignment features. This nested design allows rapid assembly through straightforward insertion and securing actions while the integrated nature of nested components reduces the number of separate parts needed, balancing assembly speed with manageable complexity

Inventive Principle:

Principle #7Nested doll (Nesting)

3Object-affected harmful factors

If higher density building is constructed to reduce land use, then environmental impact decreases, but construction costs increase due to higher elevations

Engineering Contradiction:

Improveenvironmental impactVSAvoidconstruction cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The building is divided into modular units that are constructed separately and then assembled together. Each module is a complete, self-contained unit that can be built independently, allowing parallel construction of multiple modules to improve overall productivity while maintaining ease of construction through standardized processes

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Construction tasks are performed in advance during module fabrication rather than during onsite assembly. Electrical systems, plumbing, drywall, and other interior finishes are installed while modules are being built in controlled environments, eliminating the need for workers to enter completed building units during construction and significantly improving construction efficiency

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12359439B2Modular construction connection mechanism

Publication Date: 2025.07.15 PREFABRICATED DESIGN SYST LLC

AI summary

A system for securing modular building units to each other and a method for assembling structures using said method is disclosed. The disclosed system allows for modules to be connected to each other from an external position, without a person having to enter the modules to fasten components internally. The system and method may be used to build structures using prefabricated modules, avoiding significant amounts of onsite labor and drastically reducing the time required to erect structures.