Modular Building Kit Using Unmodified Shipping Containers

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Solution Overview

Problem

Modular and kit homes often face challenges such as high costs, requirement of specialized machinery, and difficulty in transportation and design, especially when utilizing unmodified shipping containers for habitation, which are not optimized for structural modifications.

Innovation Solution

A modular building kit that includes a shipping container with prefabricated components like floor joist panels, wall sheathing, roof rafters, and foundation posts, allowing for efficient assembly into a two-level structure using manual lifts and conventional tools, eliminating the need for heavy machinery and optimizing the use of unmodified ISO containers as part of the structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If unmodified shipping containers are used for habitation, then transportation ease and structural strength are improved, but structural adaptability for habitation and ease of modification deteriorate

Engineering Contradiction:

Improvestructural strengthVSAvoidstructural adaptability

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The container structure is segmented into modular components: the container itself serves as the core structural element, while separate prefabricated modules (walls, floors, ceilings, utilities) are attached to it. This allows the container to maintain its original strength while the attached modules provide the necessary adaptability for habitation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The shipping container serves multiple functions: it provides the primary structural framework, acts as a weather-resistant shell, offers security, and serves as a transport vehicle for the complete home kit. The standardized container dimensions also enable universal transportation methods and stacking capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If specialized machinery is used for container modification, then structural modification capability is improved, but construction cost and complexity increase

Engineering Contradiction:

Improvemodification capabilityVSAvoidconstruction complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

All structural modifications and preparations are performed in advance during container manufacturing. Openings for doors and windows, structural reinforcements, and attachment points for modules are pre-configured at the factory, eliminating the need for complex on-site modification machinery and reducing construction complexity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The container is designed to be self-sufficient for assembly, using its own structural features (corner fittings, wall panels, floor beams) to facilitate module attachment without requiring external heavy machinery. The design enables manual or light-machinery assembly.

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If prefabricated components are transported separately, then design flexibility is improved, but transportation efficiency and assembly complexity increase

Engineering Contradiction:

Improvedesign flexibilityVSAvoidtransportation efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The prefabricated home modules are nested within the shipping container during transport, with walls, floors, ceilings, and utility components efficiently packed inside the container's interior space. This nested arrangement maximizes transportation efficiency while maintaining design flexibility, as modules can be configured in various arrangements within the container.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Reliability

If conventional construction methods are used, then structural integrity is improved, but construction time and cost increase

Engineering Contradiction:

Improvestructural integrityVSAvoidconstruction time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The home is divided into pre-fabricated modules that are manufactured off-site with controlled quality assurance, then quickly assembled on-site. This segmentation maintains structural integrity through factory-controlled construction while dramatically reducing on-site assembly time compared to conventional stick-building methods.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple construction activities are merged into the factory manufacturing process: structural framing, weatherproofing, insulation, electrical rough-in, and plumbing are all completed during container production. This consolidation ensures structural integrity through standardized practices while eliminating repeated on-site construction steps.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11274430B2Building structure and method of construction

Publication Date: 2022.03.15 SCILLEY JOEL

AI summary

A modular building structure that utilizes a standard, unmodified intermodal shipping container both for transport of the structural components and as an integral element of the method of construction. A modular structure kit is enclosed in the shipping container, which can be transported using all means that are standard for ISO containers. Using the preferred method of construction, the shipping container can be situated without heavy equipment. Once situated, the shipping container provides the primary support for a permanent elevated structure composed of unique components, assembled using conventional building techniques without the necessary use of heavy or specialized equipment.