Modular Building Connector Assembly for Bracing-Free Force Transfer
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Solution Overview
Problem
Current modular building construction methods face challenges in resisting and transmitting large moments, tension, and compression forces, especially in tall or slender buildings, due to the pinned nature of connections and lack of diagonal bracing, which limits the achievable height and increases costs. Additionally, existing systems are not suited for non-orthogonal shapes and require complex connections and precision cutting, increasing production time and costs.
Innovation Solution
A system of load-bearing corner blocks and gusset plates that facilitate moment connections, allowing for the assembly of modules with orthogonal, tapering, or curving shapes, while reducing the need for diagonal reinforcing elements and enabling efficient force transmission through a compact, versatile connector system that can be mass-produced and easily assembled.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pinned connections are used between modular units, then assembly is simplified and manufacturing cost is reduced, but the ability to resist and transmit large moments and tension forces is limited
Solution Approach 1:
The patent combines pinned connections with moment-resisting connections in a hybrid system. The pinned connections maintain assembly simplicity, while the moment-resisting connections (through devices like shear tabs, welded connections, or bolted flange plates) enable the structure to resist and transmit large moments and tension forces, thus resolving the contradiction between ease of manufacture and strength.
Solution Approach 2:
The connection system is segmented into different types of connections: pinned connections for simple assemblies and moment-resisting connections for load-bearing critical points. This segmentation allows each connection type to be optimized for its specific function, maintaining simplicity where needed while providing strength where required.
2Strength
If diagonal bracing is added to resist lateral forces, then structural strength is improved, but device complexity and material requirements increase
Solution Approach 1:
The moment-resisting connections serve multiple functions: they provide lateral force resistance through their inherent rigidity, eliminate the need for separate diagonal bracing elements, and maintain a relatively simple structural system. This multi-functionality resolves the contradiction by improving strength without proportionally increasing complexity.
3Strength
If large columns are used to create alternate load paths, then force transmission is improved, but useful floor area is reduced
Solution Approach 1:
The patent merges the load-bearing function with the wall/enclosure function by using moment-resisting connections at wall intersections and corners. This allows the walls themselves to act as load-bearing elements, eliminating the need for separate large columns, thus maintaining strength while preserving useful floor area.
4Strength
If secondary brace frames are constructed to transmit loads, then structural integrity is improved, but assembly time and material cost increase
Solution Approach 1:
The moment-resisting connections are integrated directly into the modular units themselves, serving both as connection elements and as part of the primary load-bearing system. This eliminates the need for separate secondary brace frames, maintaining structural integrity while significantly reducing assembly time and material requirements.
5Adaptability or versatility
If precision cutting and complex connections are used to accommodate non-orthogonal shapes, then design versatility is improved, but manufacturing complexity and production time increase
Solution Approach 1:
The patent incorporates pre-fabricated moment-resisting connection devices into the modular units during manufacturing. These pre-installed connections (such as welded flange plates, bolted connections, or integrated steel elements) are prepared in advance with precise geometry, allowing the modules to be assembled into non-orthogonal configurations without requiring complex现场 cutting or connection work, thus maintaining versatility while simplifying the manufacturing process.
Data Source
AI summary
A connector assembly, having an upper connector coupled to a lower connector and a gusset plate sandwiched between the upper and lower connectors. Also, disclosed is a hoistable connector assembly, a lifting frame assembly, a coupling system for modular frame units, a method for assembling a module unit using the connector assembly, and a modular frame unit and building having the connector assembly.