Modular Building System with Integrated Joists and Connectors

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Solution Overview

Problem

Conventional modular building systems are inefficient as they cannot be disassembled or reused, require additional frames for support, and involve on-site wet trades for assembly, leading to waste and increased costs due to the inability to reutilize modular units and the need for scaffolding.

Innovation Solution

A modular building system using prefabricated, precast concrete units with integrated load-bearing columns and joists, allowing for easy assembly and disassembly through connectors and a hoist frame system, eliminating the need for on-site concrete and additional framing, and enabling modular shear walls to handle seismic forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional modular units are assembled into complete structures, then the structures can be constructed efficiently with pre-fabricated components, but the modular units cannot be disassembled and reused in another structure

Engineering Contradiction:

Improveconstruction efficiencyVSAvoidreusability of modular units

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The modular unit is segmented into distinct functional components: load-bearing columns, joist portions, slabs, and connectors. Each component is designed as a separate replaceable element, allowing the structure to be disassembled and reconfigured. The connectors specifically enable modular connection while maintaining the integrity of individual components for future reuse.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection system transitions from permanent fixed connections to dynamic, reversible connections. The connectors allow modular units to be assembled and disassembled multiple times, providing adaptability for different construction scenarios and enabling the same modular units to serve multiple structures throughout their lifecycle.

Inventive Principle:

Principle #15Dynamics

2Ease of manufacture

If conventional modular units are used, then construction can proceed with pre-fabricated components, but additional frames are required to support the modular units once stacked

Engineering Contradiction:

Improvepre-fabrication capabilityVSAvoidadditional framing requirements

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The load-bearing columns and joist portions are merged directly into the modular unit structure itself, eliminating the need for separate external framing systems. The modular units are designed to support each other through their integrated structural elements, with columns providing vertical support and joist portions providing horizontal support, creating a self-sufficient load-bearing system.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If wet trades are employed at the construction site to couple individual modular units together, then the modular units can be connected, but the connected modular units cannot be disassembled for reuse

Engineering Contradiction:

Improveassembly capabilityVSAvoiddisassembly and reuse capability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The wet trade connection method (concrete pouring) is replaced with a mechanical connector system. The connectors use threaded rods, nuts, and coupling elements that can be assembled and disassembled using standard mechanical fastening techniques, eliminating the need for on-site concrete work and enabling repeated assembly and disassembly cycles.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of operation

If scaffolds are constructed or moved around the modular unit to enable workmen to access connection points, then the modular units can be assembled, but the process is time consuming, costly, and dangerous

Engineering Contradiction:

Improveaccess to connection pointsVSAvoidassembly time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The connection points are repositioned from vertical locations at the top of columns to horizontal locations at the ends of joist portions. This dimensional change allows workmen to access connection points at ground level or lower elevations, eliminating the need for scaffolding and improving safety while reducing assembly time.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS8919058B2Modular building system for constructing multi-story buildings

Publication Date: 2014.12.30 LIBERMAN BARNET L

AI summary

A modular building system for constructing a multi-story building includes pre-fabricated modular units. Each modular unit includes a horizontal slab for forming a floor/ceiling of the building, a joist extending horizontally along a first edge of the slab, the joist extending below the slab and extending horizontally beyond the first edge of the slab to form a receiving lip, columns positioned on top of the slab along the first edge, and connectors installed in cavities formed in the unit. A floor of the multi-story building is formed by arranging the modular units so that the slab of a first modular unit is positioned on the receiving lip of a second modular unit. An additional floor of the multi-story building is formed by arranging the modular units so that the joist portion of an upper modular unit is positioned on the columns of a lower modular unit.