Modular Frame Junction Connectors for Secure Light Steel Hoisting

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Solution Overview

Problem

Existing light steel framing in volumetric module frames faces challenges in creating secure connections without distortion or damage during hoisting, and requires complex assembly processes that are labor-intensive and inefficient.

Innovation Solution

The use of light-weight, brake-formed and roll-formed open steel sections with high-fixity connections, such as upper and lower junction connectors, to facilitate secure and efficient assembly of volumetric module frames, allowing for flush or point-loaded connections and reducing the need for skilled labor and complex equipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If light steel framing is used to create volumetric module frames, then the structure becomes lighter and easier to join, but mechanical fasteners cannot handle large point loads and the members are too weak to create secure moment connections during hoisting

Engineering Contradiction:
Improveweight of module frameVSAvoidstrength of connection during hoisting
Core Design Contradiction:
Weight of moving objectVSStrength

Solution Approach 1:

The patent applies preliminary action by pre-assembling the light steel framing into complete volumetric module frames in a factory setting before shipping to site. This allows the framing to gain initial strength and stability through pre-installed connections, enabling it to withstand hoisting loads without requiring the framing members themselves to be extremely strong. The preliminary assembly creates a rigid box structure that distributes hoisting forces across multiple points rather than concentrating them on individual weak members.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent uses intermediary elements such as reinforcing plates, connection brackets, and distributed lifting attachment points that mediate between the light steel framing members and the hoisting forces. These intermediaries transfer and distribute the large point loads from hoisting equipment across multiple framing members, preventing any single light member from bearing excessive stress that would cause failure.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Strength

If traditional structural steel is used for volumetric module frames, then strong connections can be created, but the structure becomes heavier and more difficult to assemble

Engineering Contradiction:
Improvestrength of connectionVSAvoidweight of module frame
Core Design Contradiction:
StrengthVSWeight of moving object

Solution Approach 1:

The patent applies parameter changes by modifying the connection geometry and distribution rather than changing the fundamental material strength. Light steel framing uses multiple smaller connection points distributed across the module frame rather than fewer large connections. This changes the load distribution parameters, allowing light members to collectively bear loads that would be too heavy for individual members to handle alone.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite structural system by combining light steel framing members with reinforcing elements, connection hardware, and bracing systems. While the primary framing members are lightweight, the composite system as a whole achieves the necessary strength through the synergistic combination of multiple components working together to resist hoisting and assembly loads.

Inventive Principle:
Principle #40Composite materials

3Reliability

If complex assembly processes are used to create secure connections, then reliable module assembly is achieved, but the process becomes labor-intensive and inefficient

Engineering Contradiction:
Improvereliability of module connectionVSAvoidassembly efficiency
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent applies segmentation by dividing the module frame into pre-fabricated segments with standardized connection interfaces. Each volumetric module is segmented into manageable components that can be independently assembled using repetitive, simplified connection procedures. This segmentation allows workers to focus on repeating simple connection tasks rather than performing complex custom assemblies, improving both reliability through consistency and productivity through reduced complexity.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent changes the connection parameters from complex multi-step procedures to simplified single-step or two-step connection processes. By standardizing connection geometries, pre-drilling fastener holes, and using standardized hardware, the connection reliability is maintained while the assembly time and labor requirements are significantly reduced. The connection parameters are optimized for speed without sacrificing structural integrity.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS12590452B2Systems and methods for modular construction
Publication Date: 2026.03.31 VECTOR META INC
  • US12590452B2 patent drawing
  • US12590452B2 patent drawing
  • US12590452B2 patent drawing

AI summary

A connection assembly for modular construction includes an upper junction connector coupled to an upper end of a column. The upper junction connector includes an upper end that has a planar upper surface, a recessed surface, and at least one connector sidewall extending between the upper surface and the recessed surface. The recessed surface and the at least one connector sidewall define a contiguous recessed area in the upper end that extends to second, third, and fourth edges of the upper end of the connector. A slot extends through the upper end adjacent to an interior surface of a column sidewall. A transverse bore extends through the first column sidewall proximate to and aligned with the slot.