Interlocking Modular Wall System for Precise Alignment
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Solution Overview
Problem
Building construction methods face challenges such as inconsistent quality due to human error and the difficulty in accessing utility lines within modular walls, particularly with structural insulated panels (SIPs) and insulated concrete forms (ICFs), which increases construction time and costs.
Innovation Solution
An interlocking modular wall system with offset interlocks and a quick-connect cladding system that allows for precise positioning and securement of structural wall modules, separating cladding from building envelope materials, and incorporating modular utility walls to house utilities, reducing the need for modifications and simplifying access to utility lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If prefabricated wall modules are used to construct interior and/or exterior walls, then construction speed is improved, but construction quality becomes inconsistent due to human error in positioning and securing
Solution Approach 1:
The patent introduces an interlocking system with specialized connectors and alignment features that act as intermediaries between wall modules. These intermediaries ensure precise positioning and secure connection, eliminating the need for workers to manually align and secure modules, thereby maintaining high construction speed while improving positioning accuracy.
Solution Approach 2:
The patent replaces manual mechanical positioning and securing operations with an automated interlocking mechanism. The interlocking system uses predetermined connection features that automatically align and secure wall modules when joined, substituting human manual operations with a self-aligning mechanical system that ensures consistent precision.
2Adaptability or versatility
If utility lines are incorporated into permanent walls after construction, then building functionality is improved, but construction time and cost increase due to required modifications and partial demolition
Solution Approach 1:
The patent incorporates utility lines and communication conduits into the wall modules during the prefabrication process. This preliminary action allows utility infrastructure to be pre-installed and sealed within the wall modules before they are transported to the construction site, eliminating the need for post-construction modifications and saving significant time.
Solution Approach 2:
The patent divides the building envelope into separate modular wall sections, each containing integrated utility lines and communication conduits. This segmentation allows utility infrastructure to be independently installed and sealed within each module, enabling easy assembly and connection at the site without requiring demolition or modification of the building envelope.
3Reliability
If cladding layer is added to interior and exterior wall surfaces, then aesthetic appearance and weather protection are improved, but construction complexity and time increase
Solution Approach 1:
The patent merges the cladding layer with the wall module assembly process by integrating cladding attachment features directly into the wall modules. This allows the cladding to be installed simultaneously with the wall modules during the same construction sequence, combining multiple operations into a single process and reducing overall construction complexity.
Solution Approach 2:
The patent creates a universal wall module system that can accommodate different cladding materials and configurations through standardized attachment interfaces. This multi-functionality allows the same wall module design to work with various cladding options (metal, wood, vinyl, etc.), simplifying the construction process by eliminating the need for custom designs for each cladding type.
Data Source
AI summary
Implementations of the present invention relate to systems, methods, and apparatus for constructing a building. More specifically, the present disclosure provides an interlocking wall system that can allow a builder to accurately position, orient, and/or secure various structural wall modules. Additionally, this disclosure provides systems and methods for securing one or more cladding layers to the building's envelope. Furthermore, implementations of the present disclosure can allow for quick and modifiable installation of utility and communication lines within the building.