Modular Prefab System With Interlocking Plates And Tubes
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Solution Overview
Problem
Current prefab building systems require specialized personnel, machinery, and are inflexible, leading to high construction costs and long assembly times, especially in emergency or temporary settings, due to the need for predefined plans and reliance on drying times of mortar.
Innovation Solution
A modular building system comprising plates with holes and prefabricated elements with longitudinal tubes, allowing for flexible assembly and reduced component count, enabling a single operator to assemble versatile structures without the need for wet bonding, using a base defined by plates and prefabricated elements that can form both outer and inner walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional prefab systems use predefined plans and specialized personnel, then structural stability is improved, but construction time and cost increase
Solution Approach 1:
The building system is divided into modular components (plates with holes, longitudinal elements with tubes) that can be independently manufactured and assembled. This segmentation allows for standardized production while enabling flexible assembly configurations, resolving the contradiction between structural reliability and construction speed by pre-fabricating stable components that can be quickly assembled without specialized personnel.
Solution Approach 2:
The plates and longitudinal elements are pre-fabricated with precisely positioned holes and tubes before arrival at the construction site. This preliminary action ensures structural stability is built into the components themselves, while the simplified on-site assembly process (requiring only basic tools and a single operator) dramatically reduces construction time compared to traditional methods requiring specialized teams.
2Strength
If traditional systems use machinery for handling heavy components, then assembly strength is improved, but device complexity and cost increase
Solution Approach 1:
The building system is divided into modular components (plates with holes, longitudinal elements with tubes) that can be independently manufactured and assembled. This segmentation allows for standardized production while enabling flexible assembly configurations, resolving the contradiction between structural reliability and construction speed by pre-fabricating stable components that can be quickly assembled without specialized personnel.
Solution Approach 2:
The plates and longitudinal elements are pre-fabricated with precisely positioned holes and tubes before arrival at the construction site. This preliminary action ensures structural stability is built into the components themselves, while the simplified on-site assembly process (requiring only basic tools and a single operator) dramatically reduces construction time compared to traditional methods requiring specialized teams.
3Reliability
If traditional prefab systems use mortar for bonding, then structural integrity is improved, but construction time increases due to drying requirements
Solution Approach 1:
The invention replaces the chemical bonding system (mortar that requires drying time) with a mechanical interlocking system. The longitudinal elements with tubes fit into corresponding holes in the plates, creating immediate structural integrity through friction and geometric interlocking. This mechanical connection eliminates the waiting period required for mortar to cure, allowing the structure to gain full strength immediately upon assembly.
4Manufacturing precision
If traditional systems follow predefined plans, then manufacturing precision is improved, but adaptability and versatility decrease
Solution Approach 1:
The plates are designed with multiple holes arranged in specific patterns that allow the same plate to connect with longitudinal elements at various positions and orientations. This universal design enables the standardized components to be adapted to different building configurations and layouts, maintaining manufacturing precision while providing flexibility for various building plans and emergency response scenarios.
Data Source
Figure 1~1a
Figure 1b
Figure 2a~3b
AI summary
A system for building a prefab comprising: - at least one first plate (1) provided with a plurality of first holes (3); - at least one second plate (2) provided with a plurality of second holes (4), said at least one second plate (2) being connected to and spaced apart from said at least one first plate (1); each second hole (4) being coaxial to a respective first hole (3); - a plurality of longitudinal prefabricated elements (18) provided with a respective longitudinal tube (11) defining an inner cavity (13), and a casing (12) externally covering said longitudinal tube (11) at least along part of the longitudinal extension thereof; wherein the longitudinal tube (18) has a first end (16) which comes out of the casing (12); wherein the first end (16) is adapted to be inserted into a respective second hole (4) and a respective first hole (3); and wherein the first end (16) has a length which is at least equal to the sum of the distance between the first plate (1) and the second plate (2), the thickness of the first plate (1) and the thickness of the second plate (2); whereby the at least one first plate (1) and the at least one second plate (2) define a base (36) of the prefab, and once the first end (16) of the longitudinal tube (11) is inserted into a respective second hole (4) and into a respective first hole (3), the longitudinal prefabricated elements (18) define outer walls and possibly inner walls of the prefab.