Modular Building Connector Assembly for Flexion-Resistant Expansion
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Solution Overview
Problem
Expanding the footprint of pre-existing modular buildings by connecting additional modular units poses challenges in maintaining structural strength and avoiding flexion at the interface, especially when connecting corner connectors across multiple floors.
Innovation Solution
A connector assembly comprising upper and lower connectors with gusset plates, featuring arms and bosses for secure fastening, and a method for coupling these connectors to form a stable and strong connection between modular units, allowing for efficient expansion of modular buildings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If modular units are connected to expand building footprint, then building area increases, but structural strength at connection interface deteriorates
Solution Approach 1:
The connector is divided into multiple functional components: upper connector, lower connector, gusset plate, and multiple arms. This segmentation allows each component to perform specific functions - the gusset plate distributes loads, the arms provide multiple connection points, and the modular design enables precise fitting while maintaining overall structural integrity during building expansion
Solution Approach 2:
The gusset plate acts as a counterbalancing element that distributes and redirects forces across the connection interface. By positioning the gusset plate between the upper and lower connectors, it creates a balanced force distribution system that counteracts the potential weakness at the connection point, allowing the building footprint to expand without compromising structural strength
2Length of stationary object
If corner connectors are connected across multiple floors, then building height increases, but risk of flexion at interface increases
Solution Approach 1:
The connector design incorporates local quality enhancements at critical stress points. The gusset plate is positioned specifically at the interface between upper and lower connectors to provide localized reinforcement. The arms are strategically positioned and dimensioned to provide targeted support where flexion risks are highest, allowing vertical expansion while maintaining reliability at connection interfaces
Solution Approach 2:
The connector assembly is designed and pre-assembled with all necessary structural elements in place before building expansion occurs. The gusset plate, arms, and connectors are configured in advance to ensure proper force distribution and minimize flexion risks from the outset, rather than attempting to reinforce connections after assembly
3Strength
If multiple fastening points are used to strengthen connection, then connection strength improves, but device complexity increases
Solution Approach 1:
Multiple fastening functions are merged into a single integrated connector assembly. The upper connector, lower connector, gusset plate, and arms work together as one unified structure that provides multiple fastening points simultaneously. This merging approach achieves strong connections without proportionally increasing complexity, as the components are designed to work together rather than as separate assemblies
Solution Approach 2:
The connector assembly serves multiple functions within a single design: the gusset plate provides load distribution, the arms provide multiple connection points, and the upper and lower connectors provide structural support. This multi-functionality allows the assembly to achieve high connection strength without requiring multiple separate components or complex assembly procedures
Data Source
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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. The upper and lower connectors allow for coupling to adjacent upper and lower connectors, respectively, allowing for addition of a modular unit to a pre-existing modular structure. Also, disclosed are ways of coupling adjacent upper connectors and coupling of adjacent lower connectors when coupling a modular unit to a pre-existing modular structure.