Modular Prefabricated Building System with Helical Pier Foundation

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Solution Overview

Problem

Conventional housing construction methods are costly, time-consuming, and environmentally unsustainable, particularly in low-income areas, due to the need for skilled labor, complex architectural plans, and the use of inorganic materials, while also lacking flexibility for expansion or reconfiguration.

Innovation Solution

A modular, prefabricated building system using locally sourced lumber with minimal connector hardware, allowing for rapid assembly and reconfiguration, including the use of helical piers for foundation and innovative structural connections like trusses with floating tenons and half-lap joints, enabling easy expansion, relocation, and ventilation adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional housing construction methods are used, then structural strength and stability are achieved, but construction cost and time increase significantly

Engineering Contradiction:

Improvestructural strengthVSAvoidconstruction time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The building is divided into modular components (walls, floors, roofs) that can be pre-assembled and then quickly connected on-site using simple joining mechanisms, reducing construction time while maintaining structural integrity through standardized connection points

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Modular building components are pre-assembled and prepared off-site before delivery to the construction location, allowing complex assembly work to be performed in advance and reducing on-site construction time to primarily connection and installation activities

Inventive Principle:

Principle #10Preliminary action

2Strength

If conventional housing construction methods are used, then structural strength and stability are achieved, but construction cost increases significantly

Engineering Contradiction:

Improvestructural strengthVSAvoidconstruction cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The building system uses standardized modular components that can be manufactured using simple, low-cost processes and locally sourced materials, eliminating the need for expensive specialized construction equipment and skilled labor while maintaining adequate structural strength for residential use

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The design accepts that some building components may have shorter service lives or be replaced more easily than traditional construction, using simpler, cheaper materials and assembly methods that reduce overall construction cost while meeting basic housing needs

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Stability of the object's composition

If conventional housing construction methods are used, then structural stability is achieved, but adaptability for reconfiguration and expansion is lost

Engineering Contradiction:

Improvestructural stabilityVSAvoidreconfiguration flexibility

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The building is composed of discrete modular units connected through standardized interfaces and joining mechanisms, allowing individual modules to be added, removed, or repositioned while maintaining overall structural stability through consistent connection protocols

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The building system incorporates movable and adjustable components that allow the structure to be reconfigured over time, with connection points designed to facilitate easy disassembly and reassembly for adaptation to changing user needs

Inventive Principle:

Principle #15Dynamics

4Productivity

If pre-fabricated homes are used, then construction time is reduced, but transport cost and complexity increase

Engineering Contradiction:

Improveassembly speedVSAvoidtransport weight

Core Design Contradiction:

ProductivityVSWeight of moving object

Solution Approach 1:

The building is divided into smaller modular components that can be transported using conventional vehicles and assembled on-site, avoiding the need to transport entire pre-fabricated units and reducing transport weight and cost while maintaining quick assembly benefits

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11885115B2System and method for low-cost structure fabrication and deployment

Publication Date: 2024.01.30 FUTURE EARTH INC

AI summary

There is provided a structure that is a prefabricated (or systems-built) building space including a floor assembly, modular wall assemblies, and a roof assembly. The structure may at any time be connected to one or more other structures or prefabricated room extensions to form integrated building spaces. The structure is attached in a semi-permanent connection to a helical pier foundation assembly. The structure can include a locking mechanism adapted to be removably fastened to the floor assembly and the foundation assembly.