Modular Construction Riveting and Welding for Watertight Sealing
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Solution Overview
Problem
Existing modular construction methods face issues with degradation of anti-corrosion coatings and deformation due to welding, complexity in weld assembly, and the need for specialized operators, while bolting lacks control over torque and can result in slippage, compromising the structural integrity and watertightness of the connection.
Innovation Solution
The modular construction uses riveting to assemble ceiling and floor frames with gable frames, allowing for welding only at connection areas for sealing, and manufacturing sub-assemblies in the factory to prevent damage from welding, while using assembly lugs and profiles to enhance accessibility and water drainage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to assemble floor frames, ceiling frames and end gables, then good sealing and watertightness are achieved, but anti-corrosion coatings are degraded and frames deform due to heating
Solution Approach 1:
The construction is divided into separate sub-assemblies (floor frames, ceiling frames, end gables) that are manufactured and coated independently in the factory, then assembled on-site using non-thermal riveting connections. This segmentation allows welding to be avoided entirely for frame assembly while maintaining watertightness through sealed joints in the subdivided structure.
Solution Approach 2:
Rivets serve as an intermediary connection method between the metal frames, replacing direct welding. The riveting process mechanically joins the frames without generating heat, thus preserving the anti-corrosion coatings and preventing thermal deformation while still achieving structural integrity and watertightness.
2Reliability
If welding operations are performed on large assembled construction, then complete sealing is achieved, but the complexity and difficulty of the operation increases
Solution Approach 1:
The construction is divided into smaller sub-assemblies that are manufactured separately in the factory. This segmentation reduces the size and complexity of welding operations to only small, manageable components rather than large assembled structures, making welding simpler and more controllable when it is performed.
Solution Approach 2:
All welding operations are performed in advance during factory manufacturing of sub-assemblies, before the frames are transported and assembled on-site. This preliminary action allows welding to be conducted in controlled factory conditions with proper equipment and expertise, simplifying the overall construction process.
3Ease of manufacture
If bolting is used to assemble frames, then assembly is simpler without welding, but slippage between elements occurs reducing structural stiffness
Solution Approach 1:
Rivets serve as an intermediary connection that combines advantages of both welding and bolting. Like bolting, riveting is simpler than welding and does not require thermal processes or specialized welding qualifications. Like welding, riveting creates a rigid, non-slip connection that eliminates play between holes and provides stiff, reliable joint strength.
4Reliability
If welding is used to assemble sub-assemblies, then good sealing is achieved, but protection of surrounding parts from molten metal projections is required
Solution Approach 1:
Rivets act as an intermediary connection method that eliminates the need for welding entirely during on-site assembly of frames. This removes the hazard of molten metal projections and the requirement for protective measures, while still achieving secure, sealed connections between sub-assemblies.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces the risk of sub-assembly degradation, ensures good watertightness, eliminates slippage, and simplifies the assembly process, maintaining mechanical strength and reducing operator hazards, while allowing for efficient water management and improved thermal insulation.
Implementation Method 1
each frame is equipped with assembly lugs assembled by riveting with the rails of the ceiling and floor frames
Implementation Method 2
the gutter of the or each frame is assembled by welding to the uprights of said frame
Data Source
Figure 1~1A
Figure 2~2A
Figure 3~4
AI summary
The construction has a floor frame and a ceiling frame including opposite elements (50) formed by sections. The frames are connected together by opposite frames forming end pinions of the construction. Each opposite frame includes hollow uprights (40) connected with each other by a lower cross-piece and an upper cross-piece (45). The upper cross-piece forms a gutter that is in communication, by one of ends, with an opening (405) placed in one of the uprights, and assembled with the upright by welding. The opposite frame includes mounting legs (450) assembled with the elements by riveting. An independent claim is also included for a method of assembling a modular construction.