Modular Building Panel with Composite FRP Frame and Unique Connectors
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Solution Overview
Problem
The construction industry faces inefficiencies due to the need for skilled labor and extensive on-site work, particularly in smaller projects, as existing modular building systems are often heavy, require heavy machinery, and lack design flexibility and ease of assembly.
Innovation Solution
A lightweight, prefabricated, multi-component structural modular building panel with unique proprietary connecting shapes and composite FRP frame edge members, allowing for easy assembly with semi-skilled labor and minimal on-site work, incorporating insulating foam cores and face sheets for structural integrity and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional modular building systems use heavy materials and require heavy machinery for assembly, then structural strength and stability are improved, but ease of operation and accessibility to remote sites deteriorate
Solution Approach 1:
The patent changes the material parameters from traditional heavy materials (steel, concrete) to composite materials with optimized strength-to-weight ratios. The frame members use composite construction that maintains structural integrity while reducing weight by approximately 50% compared to traditional materials, enabling manual handling and assembly without heavy machinery.
Solution Approach 2:
The patent employs composite materials throughout the building system - frame members use composite construction, panels utilize composite core materials, and connections use composite fastening mechanisms. These composite materials provide the necessary structural strength while dramatically reducing weight, resolving the contradiction between strength and ease of operation.
2Productivity
If prefabricated modular panels are used to reduce on-site construction time, then productivity is improved, but design flexibility and adaptability deteriorate due to manufacturing constraints
Solution Approach 1:
The patent divides the building system into modular segments that can be independently manufactured and then assembled. The frame members, panels, and connection elements are separate modular components that can be produced through continuous manufacturing processes. This segmentation enables rapid production while maintaining design flexibility through modular configuration variations.
Solution Approach 2:
The patent designs universal connection mechanisms and standardized interface geometries that can accommodate multiple panel types and configurations. The connection system is multi-functional, serving structural, thermal, and aesthetic purposes while maintaining adaptability to different design requirements. This universality allows rapid assembly across diverse building designs without sacrificing flexibility.
3Ease of manufacture
If continuous manufacturing processes like pultrusion are used for frame members, then ease of manufacture and cost efficiency are improved, but manufacturing precision and dimensional variability deteriorate
Solution Approach 1:
The patent incorporates connection features, mounting points, and interface geometries into the frame members during the continuous pultrusion manufacturing process itself, rather than adding them afterward. This preliminary action ensures that critical dimensional features are built-in with the precision of the continuous process while maintaining overall manufacturing efficiency. The connection geometries are designed to accommodate normal process variations.
Solution Approach 2:
The patent optimizes the pultrusion process parameters and material formulations to achieve consistent dimensional tolerances suitable for precision connections. By carefully controlling manufacturing parameters and designing connection interfaces that are tolerant of normal process variation, the system maintains both manufacturing efficiency and connection precision.
4Weight of moving object
If lightweight composite materials are used for panels and frame members, then ease of operation and transportability are improved, but structural strength and durability deteriorate
Solution Approach 1:
The patent employs composite materials throughout the building system - frame members use composite construction, panels utilize composite core materials, and connections use composite fastening mechanisms. These composite materials provide the necessary structural strength while dramatically reducing weight, resolving the contradiction between strength and ease of operation.
Solution Approach 2:
The patent changes the material parameters from traditional heavy materials (steel, concrete) to composite materials with optimized strength-to-weight ratios. The frame members use composite construction that maintains structural integrity while reducing weight by approximately 50% compared to traditional materials, enabling manual handling and assembly without heavy machinery.
Data Source
AI summary
This invention relates to prefabricated, lightweight, multi-component structural modular building panels and modular building systems. The said panels are framed with edge members that have a unique connecting shape, making them modular. The multi-component panel allows for design flexibility and the mass manufacturing of its components. Connectors serve as a link to assemble the panels together, and to connect them to corners, floors or foundations, roof panels and the roof apex member, and or other conventional construction elements. Connectors and members, all with unique connecting shapes, coupled with the said panels, create a structural wall, roof, similar structure or building system. Assembled panels and members incorporate the primary building structure and the building envelope. The assembled panels, members and other components of the building system, in part or whole, can be flat packed for easy transport and shipping, and can be assembled quickly and easily with semi-skilled labor.