Modular Building Connector Assembly for Moment-Resisting Joints
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Solution Overview
Problem
Existing modular building construction methods face challenges in resisting wind, seismic, and gravity forces, particularly in tall or slender buildings, due to limitations in force transmission and increased material costs, while also requiring complex connections and precision operations, which hinder efficient assembly and space utilization.
Innovation Solution
A system of load-bearing corner blocks and gusset plates that facilitate moment connections, allowing for the assembly of modules with non-orthogonal shapes, reducing the need for diagonal bracing and enabling efficient force transmission through a compact, versatile connector system that minimizes precision cutting and welding operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional pinned connections and diagonal bracing are used in modular buildings, then assembly is simplified and shipping integrity is maintained, but the ability to resist and transmit large moments and tension forces from wind, seismic, and gravity loads is limited
Solution Approach 1:
The connector is divided into multiple functional components: a body portion receiving the structural member, an arm portion extending therefrom, a locating pin for positioning, and an aperture for fastener engagement. This segmentation allows each component to perform its specific function efficiently while collectively providing moment-resisting capability without requiring complex diagonal bracing systems.
Solution Approach 2:
The invention transitions from two-dimensional pinned connections to three-dimensional moment connections by adding vertical arm portions that extend above and below the module interface. This dimensional extension enables the connection to resist moments in multiple directions, transforming the connection from a simple pin joint to a rigid moment-resisting joint.
2Strength
If all modules are reinforced to resist forces in a distributed fashion, then force resistance is improved, but material usage and production costs increase
Solution Approach 1:
Instead of uniformly reinforcing all modules, the invention concentrates reinforcement at critical connection locations through localized connector components. The arm portions, locating pins, and fastener apertures are strategically positioned at module interfaces where forces are transmitted, allowing standard modules to maintain their original design while achieving enhanced overall structure strength.
Solution Approach 2:
The moment-resisting capability is built into the connector design during manufacturing, with pre-positioned locating pins and apertures that guide fastener installation. This preliminary configuration ensures proper force transmission paths are established before loading occurs, eliminating the need for additional reinforcement materials in the modules themselves.
3Strength
If large columns are employed to create alternate load paths, then force transmission is improved, but floor area is reduced due to larger spaces between modules and increased wall thickness
Solution Approach 1:
The invention merges the column function with the wall module interface by integrating moment-resisting connectors directly into the module corner blocks. This eliminates the need for separate large columns, as the wall modules themselves become load-bearing elements that transmit forces vertically and laterally through the rigid connections, thereby maximizing usable floor area.
Solution Approach 2:
The connector assembly serves multiple functions simultaneously: it provides moment resistance, establishes locating pins for alignment, creates fastener apertures for structural attachment, and enables hoisting operations. This multi-functionality eliminates the need for dedicated column elements, allowing wall modules to serve both enclosure and structural load-bearing purposes.
4Manufacturing precision
If precision cutting and welding operations are performed to create accurate module connections, then connection accuracy is improved, but assembly time and production cost increase
Solution Approach 1:
The connector body and arm portions are pre-configured with locating pins and apertures during manufacturing. These pre-positioned features guide module alignment and fastener installation, ensuring accurate connections without requiring complex precision cutting or welding operations during assembly. The preliminary configuration of connection geometry translates to both accuracy and speed.
Solution Approach 2:
The locating pins and apertures in the connector design enable self-aligning and self-positioning of modules during assembly. The geometry of the connector components automatically guides proper placement and orientation, reducing the need for skilled precision work and specialized equipment, thereby increasing assembly productivity while maintaining connection accuracy.
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.