Modular Housing Connector Systems With Integrated Wall Conduits
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Solution Overview
Problem
Existing modular construction technologies face challenges with finding suitable materials and assembly issues, limiting their widespread adoption due to inefficiencies and increased costs.
Innovation Solution
Utilization of fiber-reinforced plastic materials, particularly fiberglass, for constructing modular housing components, including wall panels and flooring, with integrated insulation and conduits, and a connection system that allows for efficient assembly and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional modular construction materials and methods are used, then assembly processes are simpler, but construction efficiency is reduced and costs increase
Solution Approach 1:
The housing structure is divided into multiple pre-fabricated modular panels that can be manufactured separately and assembled on-site. Each panel is a self-contained unit with standardized dimensions and integrated components, enabling parallel manufacturing and streamlined assembly processes that improve construction efficiency without overwhelming complexity
Solution Approach 2:
Insulation layers, wiring conduits, and other building systems are pre-installed within the modular panels during manufacturing before the panels reach the construction site. This preliminary action eliminates on-site installation steps, reduces construction time, and improves efficiency while maintaining manageable assembly procedures
2Reliability
If fiber-reinforced plastic materials are used, then durability and insulation are improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs fiber-reinforced plastic composites combining fiberglass or carbon fiber with polymer matrices to create panels with enhanced strength, durability, and thermal insulation properties. These composite materials provide superior performance compared to traditional materials while being amenable to automated manufacturing processes
Solution Approach 2:
The manufacturing process utilizes controlled parameters including resin injection pressure, fiber orientation, and curing temperature to optimize the properties of fiber-reinforced plastic panels. By precisely controlling these parameters, the system achieves high durability and insulation performance while maintaining manufacturing efficiency through automated processing
3Temperature
If integrated insulation and conduits are incorporated, then thermal performance is improved, but assembly time increases
Solution Approach 1:
Insulation layers and wiring conduits are integrated directly into the modular panel structure during manufacturing, merging multiple building systems into unified components. This integration ensures proper thermal performance while eliminating separate installation steps, actually reducing overall assembly time despite the added complexity of integrated features
Solution Approach 2:
Wiring conduits and insulation elements are nested within the modular panel cavities and structural layers during manufacturing. This nesting approach allows multiple functional elements to be housed within the same spatial envelope, maintaining thermal performance while simplifying on-site assembly to a single panel installation operation
Data Source
AI summary
A modular construction housing system includes fiber-reinforced wall panels, such as fiberglass wall panels, attached to a roof component via one or more pins extending downwardly from the roof component into an internal cavity of the wall panels. The wall panels and the flooring of the modular construction housing system are integrally formed via molding to reduce the number of separate components and the amount of construction and connection required on-site. The wall panels include a plurality of internal conduits extending through the internal cavity of the wall panels configured to align with internal conduits extending downward from the roof component to allow for electrical wiring and other function to seamlessly extend from the wall to the roof.