Modular Housing with Demountable Transport Panels

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Solution Overview

Problem

Modular building construction faces challenges in maximizing factory completion and efficient transportation due to dimensional limitations and protection issues, leading to increased fieldwork and costs, with existing solutions either compromising structural integrity or requiring extensive site work to make modules habitable.

Innovation Solution

A method and system for constructing fully finished building modules with integrated demountable transport panels, allowing for complete installation of exterior claddings, windows, doors, interior finishes, and systems in the factory, which can be transported using the intermodal shipping network and assembled on-site with minimal field work.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If modules are built to maximum roadway dimensions (12x14.5x30-60 feet), then the number of modules needed is reduced, but delivery costs increase due to specialized trucks and routes

Engineering Contradiction:

Improvenumber of modulesVSAvoiddelivery cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The building is divided into multiple smaller modules that can be transported using standard shipping containers and intermodal transportation networks. Instead of using fewer large modules that require specialized delivery, the system segments the building into transportable units that leverage existing infrastructure, reducing delivery costs while maintaining productivity.

Inventive Principle:

Principle #1Segmentation

2Productivity

If exterior finishes and windows are installed in the factory, then assembly line efficiency is maximized, but modules become vulnerable to damage during transport

Engineering Contradiction:

Improveassembly line efficiencyVSAvoidprotection from damage

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Exterior finishes, windows, and doors are installed in the factory before transport, maximizing assembly line efficiency. The modules are then protected during transport using shrink wrap and strategic placement in shipping containers, allowing finished modules to be delivered without requiring additional field work.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Shipping containers serve as an intermediary protective environment during transport. Modules are placed within containers that provide structural protection, and additional shrink wrap is applied to protect exterior finishes. This intermediary system allows finished modules to be transported safely using standard intermodal infrastructure.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If modules are transported long distances, then regional limitations are overcome, but delivery costs become prohibitive

Engineering Contradiction:

Improvegeographic reachVSAvoiddelivery cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The system uses standard shipping containers and intermodal transportation networks that are universally available globally. This allows modules to be transported to any location with access to standard shipping infrastructure, overcoming regional limitations and enabling factories to serve international markets without incurring prohibitive specialized delivery costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Ease of manufacture

If minimum protection (shrink wrap) is used during transport, then delivery costs are minimized, but finish materials and assemblies are damaged

Engineering Contradiction:

Improvedelivery costVSAvoidprotection adequacy

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Multiple layers of protection are applied beforehand: exterior finishes are installed in the factory, then modules are wrapped in shrink wrap, and finally modules are strategically placed within shipping containers. This layered protective approach ensures finish materials are adequately protected during transport without significantly increasing delivery costs.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS9121168B2Modular housing

Publication Date: 2015.09.01 HOME EC

AI summary

A volumetric module that can have all of its exterior claddings, windows, doors, interior finishes, cabinetry, plumbing, electrical, mechanical, and roofing installed and completed in the factory minimizing work to be completed in the field, and a method to protect the fully finished building module during transport with a series of demountable transport panels. The finished and protected building module is transported to a site utilizing the intermodal shipping network or by different modes of shipping and transportation. At the building site, the finished building module is placed on a foundation or other form of support, the transport panels are removed from the module revealing a fully finished building module suitable for use as a habitable building both in it singular use as well as the creation of a larger habitable building by joining finished building modules at the building site.