Modular Concrete Building Panel Interlocking
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Solution Overview
Problem
The existing methods for constructing modular buildings, particularly those using precast concrete panels, face challenges in ensuring precise assembly and securing roof panels effectively, often relying on flat or non-concrete roofs which may not be structurally optimal.
Innovation Solution
A method for assembling a modular concrete building that involves a foundation, support members, floor panels, wall panels, and roof panels, where support columns and beams are securely anchored to the foundation, and panels are interconnected using securing members and fixation mechanisms, allowing for precise placement and secure attachment of roof panels to wall panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If precast concrete panels are used for modular buildings, then structural durability is improved, but assembly precision and roof panel securing become more difficult
Solution Approach 1:
The building is divided into modular precast concrete panels (wall panels, floor panels, roof panels) that can be manufactured separately with high precision and assembled on-site. Each panel is a self-contained module with integrated connection features, allowing for precise assembly while maintaining structural durability.
Solution Approach 2:
Connection features such as recesses, protrusions, and securing members are pre-formed during panel manufacturing. This preliminary action ensures that when panels are assembled on-site, the connection points are already prepared for precise alignment and secure attachment, eliminating the need for complex field adjustments.
2Ease of operation
If traditional securing methods are used for roof panels, then installation simplicity is maintained, but roof panel security and structural integrity are compromised
Solution Approach 1:
The roof panel connection system uses a nested structure where a protrusion on one panel fits into a recess on the adjacent panel, creating an interlocking arrangement. This nested design provides secure mechanical connection while maintaining installation simplicity through intuitive alignment and attachment.
Solution Approach 2:
The securing members and connection features are integrated directly into the roof panels themselves, allowing the panels to secure each other without requiring external fastening systems or additional components. The panels perform their own securing function through their inherent design features.
3Manufacturing precision
If extreme precision is required in wall panel construction, then fit quality is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The building envelope is segmented into standardized wall panels with consistent dimensions and pre-formed connection features. This segmentation allows for repeated manufacturing processes that achieve high precision through automation and standardization, rather than requiring complex custom fabrication for each panel.
Solution Approach 2:
The wall panels are designed with universal connection features (recesses and protrusions) that can be used across all panels regardless of their specific location in the building. This universality simplifies manufacturing by using the same connection design throughout, reducing complexity while maintaining fit quality through consistent precision standards.
Data Source
AI summary
A modular concrete building is made of a plurality of precast concrete panels which may be assembled to provide a building. The panel sections include lower frame panels or support members, wall panels, floor panels, and flat roof panels. The building may be assembled by securing the floor panels to the support members, securing the wall panels to the floor panels, and securing the roof panels to the wall panels and to adjacent roof panels. The roof panels may have rigid insulation. The roof panels may have tapered rigid insulation or the modular building may be constructed with the roof panels in a tilted position.