Modular Building Connector Assembly for Moment-Resisting Load Paths
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Solution Overview
Problem
Existing modular building construction methods struggle to efficiently resist and transmit large moments, tension, and compression forces, especially in tall or slender buildings, while maintaining economic viability and minimizing material use and construction time, and are limited by the need for precise assembly and complex connections, particularly in non-orthogonal shapes.
Innovation Solution
A system of load-bearing connectors and components, including corner blocks, gusset plates, and hoisting connectors, that facilitate accurate and efficient assembly of modular frames, allowing for quick rigging and hoisting, and provide continuous load paths without excessive unfinished areas, accommodating various building shapes and reducing the need for complex connections and precision cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional modular construction methods are used with pinned connections, then assembly is simpler and faster, but the ability to resist and transmit large moments and tension forces is limited
Solution Approach 1:
The connector is divided into multiple functional components: a body portion that interfaces with the modular unit frame, an extension portion that provides moment resistance, and a bracing interface that enables diagonal bracing integration. This segmentation allows each component to specialize in resisting specific force types while maintaining overall connection simplicity.
Solution Approach 2:
The connector transitions from traditional planar pinned connections to a three-dimensional moment-resisting connection by adding the extension portion that projects perpendicular to the frame member. This dimensional addition enables the connection to resist moments about multiple axes simultaneously.
2Strength
If large columns are employed to create alternate load paths, then force transmission improves, but wall thickness increases and useful floor area is reduced
Solution Approach 1:
Instead of increasing column size throughout the entire wall assembly, the invention concentrates structural reinforcement locally at the connector components. The extension portion and bracing interface provide localized moment resistance and force transmission without requiring increased wall thickness or reduced floor area elsewhere in the modular unit.
3Strength
If secondary frames are constructed to transmit loads, then structural capacity increases, but assembly time and material cost increase
Solution Approach 1:
The invention merges the functions of the connector body, moment-resisting extension, and bracing interface into a single integrated connector assembly that attaches to the modular unit frame. This consolidation eliminates the need for separate secondary frames while maintaining all necessary structural functions, thereby reducing assembly steps and material requirements.
4Reliability
If precise assembly and complex connections are required, then structural integrity improves, but construction time and cost increase
Solution Approach 1:
The connector is pre-assembled and pre-configured with its body portion, extension portion, and bracing interface in the correct spatial relationships before being installed on the modular unit. This preliminary assembly ensures proper alignment and structural integrity while eliminating time-consuming on-site alignment and adjustment operations.
Solution Approach 2:
The connector design incorporates self-aligning features and self-contained structural elements that automatically ensure proper installation without requiring complex external alignment tools or multiple assembly steps. The extension portion and bracing interface are configured to self-position relative to the frame member, ensuring structural integrity through the connector's own geometry rather than external constraints.
Data Source
AI summary
A connector assembly, having an upper connector coupled to a lower connector and a gusset plate sandwiched between the upper and lower connectors. Also, disclosed is a hoistable connector assembly, a lifting frame assembly, a coupling system for modular frame units, a method for assembling a module unit using the connector assembly, and a modular frame unit and building having the connector assembly.