Modular Panel Keyway Interlock for Precise Angle Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current modular construction systems face challenges in efficiently interlocking panels to form extended wall sections with precise angles and configurations, which affects the structural integrity and ease of assembly in building construction.
Innovation Solution
The modular construction system incorporates keyway receivers and splines with angled offset faces and walls, allowing panels to be interlocked with specific angle configurations, enabling precise alignment and secure coupling of adjacent panels to form extended wall sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional modular construction systems use simple rectangular connections, then manufacturing is easier, but structural integrity and alignment precision deteriorate
Solution Approach 1:
The connection structure is divided into separate keyway receiver and keyway spline components that can be independently manufactured and then assembled. This segmentation allows each component to be optimized for its specific function while maintaining overall structural integrity, resolving the contradiction between strength and manufacturing complexity.
Solution Approach 2:
The keyway receiver and keyway spline feature asymmetric angled faces (first and second offset faces) rather than simple rectangular geometries. This asymmetry enables precise angular alignment and interlocking that enhances structural strength while the standardized asymmetric design actually simplifies manufacturing compared to custom fitted connections.
2Manufacturing precision
If modular panels use complex angled keyway configurations, then alignment precision improves, but ease of assembly deteriorates
Solution Approach 1:
The keyway receiver and keyway spline are designed to self-align through their complementary angled geometries. When panels are brought together, the asymmetric offset faces naturally guide the components into precise alignment without requiring external alignment tools or complex adjustment procedures, thereby maintaining ease of assembly while achieving high precision.
Solution Approach 2:
The keyway spline acts as an intermediary element that mediates the connection between panels. Its specially shaped faces with specific angles serve as the interface that transfers and distributes loads while maintaining precise angular relationships, simplifying the assembly process by providing a ready-made alignment mechanism.
3Strength
If panels are assembled with precise angle configurations, then structural integrity improves, but assembly time increases
Solution Approach 1:
The precise angular configurations and interlocking geometries are pre-designed and pre-manufactured into the keyway receiver and keyway spline components during panel fabrication. This preliminary action ensures that when panels are assembled on-site, the precise angular relationships are already built-in, allowing for rapid assembly without time-consuming field adjustments while maintaining structural integrity.
Data Source
AI summary
Modular construction panels, systems, and methods of installation are set forth for use in creating buildings. A modular construction panel includes a panel having a height, opposed faces, and opposed generally vertical ends. In one embodiment, a keyway receiver is integral with the panel adjacent one of the ends, and a keyway spline is integral with the panel adjacent the other end. In another embodiment, a keyway receiver is integral with the panel adjacent one of the ends. In still another embodiment, a keyway receiver is integral with the panel adjacent one of the ends. One modular construction system includes first and second panels, each having: a height, opposed faces, opposed generally vertical first and second ends, a keyway receiver at the first end or one of the faces adjacent the first end, and a keyway spline at the second end or one of the faces adjacent the second end.