Modular House Building System With Interstitial Planks
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Solution Overview
Problem
Existing modular house construction systems lack flexibility and strength in configuration, as they often require complex on-site assembly and do not provide precise dimensional control or robust structural integrity.
Innovation Solution
A modular house building system comprising pre-assembled floor, wall, and door modules with interstitial planks for enhanced strength, connected using mechanical fasteners like nails, bolts, and screws, allowing for various configurations and precise dimensional adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional modular construction systems are used, then assembly can be performed on-site, but the structural strength and dimensional precision are insufficient
Solution Approach 1:
The patent applies preliminary action by pre-assembling complete wall modules, floor modules, and roof modules in controlled factory environments before transport to the construction site. Each module is pre-configured with precise dimensions, pre-installed windows and doors, and pre-attached structural components. This advance preparation ensures both high manufacturing precision and structural strength, as modules are built under controlled conditions with quality assurance protocols, then simply connected on-site using standardized fastening systems.
2Strength
If modular modules are pre-assembled with interstitial planks, then structural strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the house into discrete, standardized modules (wall modules, floor modules, roof modules) that can be independently manufactured and assembled. Each module is further segmented into standardized components: vertical studs, horizontal planks, and interstitial planks positioned at regular intervals. This segmentation allows for simplified mass production of identical components, reducing overall manufacturing complexity despite the added strength from interstitial planks.
Solution Approach 2:
The patent applies parameter changes by standardizing the dimensions, spacing, and positioning of structural elements across all modules. Interstitial planks are positioned at fixed intervals (e.g., every 16 or 24 inches) and all modules use consistent stud spacing, plank thicknesses, and connection hole patterns. This standardization transforms the complex task of custom module construction into a repeatable manufacturing process with controlled parameters, reducing complexity while maintaining or enhancing structural strength.
3Reliability
If modules are connected with multiple fasteners, then structural integrity is improved, but assembly time increases
Solution Approach 1:
The patent applies preliminary action by pre-drilling and pre-positioning fastener holes in modules during factory assembly. Alignment features such as guide pins, tapered holes, and keyed connections are pre-configured to ensure automatic alignment when modules are joined on-site. This preliminary preparation allows workers to simply insert and tighten fasteners without time-consuming measurement, alignment, or drilling operations, thereby maintaining high connection reliability while dramatically reducing assembly time.
4Manufacturing precision
If floor support modules use overlapping planks, then dimensional precision is improved, but material usage increases
Solution Approach 1:
The patent applies the nesting principle by designing floor support modules where planks from adjacent modules overlap and interlock, with each module's planks partially containing or supporting those of neighboring modules. The overlapping planks are positioned in nested configurations where upper planks rest upon or are secured to lower planks from adjacent units. This nesting arrangement achieves precise dimensional control through the interlocking geometry while optimizing material usage by allowing shared structural elements between modules, reducing total material requirements compared to non-overlapping designs.
Data Source
AI summary
A modular house building system has floor module supports; floor modules; wall modules; window panel modules; door panel modules; and fasteners, wherein the modules are connected to one another in any of a number of configurations using the fasteners to form a chosen modular house configuration; wherein the wall, window panel, and door panel modules each include horizontal planks, vertical planks that define an outer perimeter of each the module, and interstitial planks connected between the vertical planks that are used to increase the strength of each the module, and are connected together in any one of a plurality of configurations to form each respective module in a pre-chosen dimension and configuration.