Modular floor cassette
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Solution Overview
Problem
Traditional modular homes require numerous skilled tradesmen for on-site installation of operational features like HVAC, plumbing, and IT systems, leading to inefficiencies and increased costs.
Innovation Solution
A prefabricated floor cassette integrating HVAC, plumbing, electrical, and IT systems, using thermoformed plastic with integrated ducting, drainage, and distribution systems, allowing remote monitoring and minimizing the need for on-site installations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional modular homes are constructed with separate subunits assembled on-site, then structural robustness is improved, but installation complexity and time increase due to requiring numerous skilled tradesmen
Solution Approach 1:
The patent combines HVAC ducting, plumbing drainage, electrical wiring, and IT cabling into a single integrated floor cassette assembly. This merging of multiple separate systems into one pre-assembled unit reduces on-site installation complexity while maintaining the structural robustness of modular construction.
Solution Approach 2:
The floor cassette is pre-assembled in a factory setting with all operational features (HVAC, plumbing, electrical, IT) installed before shipping to the job site. This preliminary action eliminates the need for skilled tradesmen to perform complex on-site installations, reducing both installation time and complexity.
2Reliability
If multiple operational features are installed separately on-site, then system reliability is improved through specialized installation, but productivity decreases due to extended installation time
Solution Approach 1:
All operational features are pre-installed in the floor cassette during factory manufacturing, allowing quality control and testing to be performed under controlled conditions. This maintains system reliability while significantly improving installation productivity, as the entire cassette is installed as one unit rather than having multiple tradesmen work separately on-site.
Solution Approach 2:
The floor cassette is designed as a modular, self-contained unit that can be independently manufactured, tested, and installed. This segmentation allows for specialized factory production of each cassette while simplifying on-site installation, thereby maintaining reliability through controlled manufacturing and improving productivity through reduced installation time.
3Loss of time
If integrated systems are pre-assembled in the floor cassette, then installation time is reduced, but manufacturing complexity increases
Solution Approach 1:
The floor cassette is designed as a standardized, modular component with defined dimensions and interfaces. This segmentation allows for efficient factory production using automated manufacturing processes, reducing the impact of manufacturing complexity while enabling rapid on-site installation that minimizes installation time.
Solution Approach 2:
The floor cassette is designed as a universal assembly that can accommodate multiple operational features (HVAC, plumbing, electrical, IT) within a single standardized structure. This multi-functionality allows for streamlined manufacturing processes while providing comprehensive building systems, thereby reducing installation time without proportionally increasing manufacturing complexity.
4Adaptability or versatility
If perimeter drain cavity is used for multiple purposes (drainage, air duct, electrical raceway), then space utilization is improved, but system reliability may worsen due to potential interference between functions
Solution Approach 1:
The perimeter drain cavity is designed with localized functional zones where different systems (drainage, HVAC air ducts, electrical raceways, IT cabling) are spatially separated and routed through specific sections. This local differentiation of quality within the unified cavity structure allows for efficient space utilization while preventing interference between different system functions, thereby maintaining reliability.
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
Enables efficient, cost-effective construction and remote management of modular homes by reducing the need for on-site trades, enhancing water drainage, and providing integrated systems for HVAC, electrical, and IT distribution.
Implementation Method 1
a perimeter drain incorporated into a perimeter of the base, where the perimeter drain comprises a cavity designed to collect liquid from the floor of the modular housing unit
Implementation Method 2
The cavity of the perimeter drain also comprises an air duct that delivers heated or cooled air to the modular housing unit
Implementation Method 3
an air duct that delivers heated or cooled air to the modular housing unit
Data Source
AI summary
A floor cassette for a housing module includes a base that is sized to fit under a floor of the modular housing unit. The floor cassette also includes a perimeter drain incorporated into a perimeter of the base, where the perimeter drain comprises a cavity designed to collect liquid from the floor of the modular housing unit. The cavity of the perimeter drain also comprises an air duct that delivers heated or cooled air to the modular housing unit.