Modular Floor Assembly Slot Joist Installation
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Solution Overview
Problem
Modular building unit construction is hindered by the labor-intensive and time-consuming process of attaching floor assemblies, which requires multiple personnel and involves inverting the frame for installation.
Innovation Solution
A floor assembly design featuring side rails and joists with slots that allow sub-floor sheets to be installed from above without welding, rivets, or screws, eliminating the need to invert the frame and reducing the number of personnel required for installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional floor assembly installation method is used, then the floor assembly can be securely attached to the frame, but the installation process requires inverting the frame and multiple personnel, making it labor-intensive and time-consuming
Solution Approach 1:
The patent inverts the traditional installation approach by designing the floor assembly to be installed from the accessible side rather than requiring frame inversion. The subsheet is configured with engagement features that allow installation from above, eliminating the need to invert the entire floor assembly frame and reducing installation complexity
Solution Approach 2:
The floor assembly is segmented into modular components including the subsheet, framing members, and interchangeable fasteners. This segmentation allows each component to be independently installed and positioned, enabling simpler installation procedures without requiring complete frame inversion or multiple personnel coordinating complex maneuvers
2Ease of manufacture
If traditional floor assembly installation method is used, then the floor assembly can be securely attached to the frame, but the process requires welding, rivets, or screws, increasing complexity and labor requirements
Solution Approach 1:
The subsheet incorporates self-engagement features such as bent edges and slots that automatically engage with the framing members during installation. This self-service mechanism eliminates the need for external fastening tools, welding equipment, or rivet guns, allowing the floor assembly to secure itself through simple placement and minimal fastening
Solution Approach 2:
The patent extracts the complex fastening operations (welding, riveting, screwing) from the installation process by designing integrated engagement features directly into the subsheet and framing members. The essential securing function is retained while removing the need for separate fastening tools and complex assembly procedures
Data Source
AI summary
Disclosed is a floor assembly for a modular building unit that avoids the need to turn the floor assembly frame over for installation of a floor subsheet, and that likewise provides a modular floor subsheet that may be fitted to the modular building unit without welding, rivets, screws, or other tooling. A floor assembly frame includes side rails that form the exterior, bottom perimeter of the modular building unit, and joists that extent between parallel side rails of the floor assembly frame. The joists are configured at their base on one side with a slot configured to receive one end of a section of a floor subsheet. An opposite end of the floor subsheet is then positioned overtop the joist element that forms the top portion of the slot on an adjacent joist, which opposite end may then be held in place with a pin, clip, or other fastener requiring minimal effort to install. Such assembly allows all components of the floor to be installed from above, thus avoiding the need to invert the frame of the floor assembly during installation. Likewise, the modular nature of the assembly allows installation to be carried out by fewer personnel than required in traditional installations.