Interlocking Synthetic Modular Building Components
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Solution Overview
Problem
Conventional building methods require tools and labor for assembly, and existing prefabricated structures lack interlocking components with square corners and sturdy, weather-resistant features.
Innovation Solution
A modular structure composed of lightweight synthetic components with interlocking designs, including stud members with honeycomb cores, slip connectors, and corner connectors, allowing for tool-free assembly and forming a sturdy, weather-resistant framework.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional lumber and building materials are used, then the structure requires tools and skilled labor for assembly, but the structure achieves adequate strength and stability
Solution Approach 1:
The structure is divided into modular components (posts, beams, panels) with standardized interlocking features. Each component is pre-fabricated with specific geometric features that enable tool-free assembly through simple insertion and locking mechanisms, eliminating the need for complex cutting and fastening operations required by conventional lumber.
Solution Approach 2:
Components are designed with nested interlocking features where smaller elements fit within or between larger structural members. The panel components nest between posts and beams, and internal truss elements are nested within panel structures, creating a hierarchical assembly system that simplifies construction sequencing.
2Weight of moving object
If lightweight synthetic materials are used, then the structure weight is reduced and assembly is simplified, but the structure must achieve adequate weather resistance and structural strength
Solution Approach 1:
The structure employs composite construction combining synthetic materials (resistant to rot and insects) with design features that provide structural integrity. The interlocking geometric features and truss configurations create composite structural systems where the arrangement and connection of components provide strength comparable to or exceeding conventional materials, while the synthetic material composition provides superior resistance to environmental degradation.
3Productivity
If prefabricated components are used, then assembly time is reduced, but the components must achieve precise interlocking for square corners and sturdy construction
Solution Approach 1:
All precision work is performed during manufacturing of individual components rather than during assembly. Posts, beams, and panels are pre-cut, pre-drilled, and pre-shaped with exact geometric features that ensure proper fit and square corners when assembled. This preliminary preparation of components with precise dimensions and features enables rapid assembly without requiring high precision during the construction phase.
Solution Approach 2:
The interlocking features are designed to be self-aligning and self-securing. Geometric shapes on component surfaces automatically guide proper positioning and orientation during assembly, with built-in locking mechanisms that secure components in place through simple insertion motions. The design provides self-checking features where proper fit is evident from the assembly process itself, eliminating the need for complex measurement and adjustment procedures.
Data Source
AI summary
A modular structure assembled with different prefabricated and measured interlocking component elements made from a light-weight synthetic material. The component elements, including vertical stud members, horizontal support members, wall truss support members, rafter members, slip connector members, corner connector members, and a center truss support member, are assembled in an interlocking manner with optional secondary fastening components for further securing of the elements together upon assembly where local building codes require such secondary fastening. The component elements are resistant to weather, rot and insect destruction and the assembly of the modular structure does not require tools or labor required in the assembly of structures using conventional building materials or lumber.