Modular Building Reinforcing Structure for Long-Span Construction
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Solution Overview
Problem
Modular building construction faces challenges in creating large open spaces without the need for disruptive and costly support structures like walls, columns, or beams, which interfere with aesthetics and require extensive installation efforts.
Innovation Solution
Integration of a reinforcing structure into modular building units, comprising vertical posts and diagonal members connected with fasteners, allowing the module to function as a structural truss and span distances without underlying support, using materials like dimensional lumber, metal, or cable, to enhance structural integrity and eliminate the need for traditional support elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional support structures (walls, columns, beams) are used to span large distances, then structural support is provided, but aesthetic quality deteriorates and construction cost increases
Solution Approach 1:
The patent extracts and removes traditional support structures (walls, columns, beams) from the modular building design, replacing them with a long-spanning truss system that eliminates the need for intermediate supports. This extraction of unnecessary elements directly improves aesthetic quality while maintaining structural strength through the integrated truss design.
Solution Approach 2:
The truss structure serves multiple functions simultaneously: it provides structural support for spanning large distances, defines the building envelope, and creates open interior spaces. This multi-functionality eliminates the need for separate support structures, thereby improving aesthetics while maintaining structural integrity.
2Strength
If traditional support structures are used, then structural integrity is maintained, but construction time and complexity increase
Solution Approach 1:
The building is divided into modular units that can be pre-assembled with truss structures in a controlled factory environment. This segmentation allows for parallel construction of multiple modules, reducing overall construction time while maintaining structural integrity through standardized, pre-engineered truss systems.
Solution Approach 2:
The truss structures and modular units are pre-assembled and pre-engineered before final installation at the construction site. This preliminary action includes manufacturing trusses off-site, pre-installing building components, and preparing modules for rapid deployment, thereby significantly reducing on-site construction time while ensuring structural integrity through quality-controlled assembly.
3Productivity
If modular units are designed to span large distances without support, then aesthetic quality and construction efficiency improve, but structural requirements become more demanding
Solution Approach 1:
The truss structures utilize composite construction combining wood members with metal connectors and fastening systems. This composite approach allows the wooden modular units to achieve the necessary span capabilities and structural strength while maintaining the benefits of wood construction, thereby meeting demanding structural requirements without sacrificing construction efficiency.
Solution Approach 2:
The patent transitions from traditional two-dimensional wall-supported construction to three-dimensional truss-based spatial structures. This dimensional change allows loads to be distributed through multiple pathways in three dimensions, enabling longer spans and larger open spaces while maintaining structural efficiency and construction productivity.
Data Source
AI summary
Modular building units comprise, prior to installation at a construction site, a floor, a ceiling, and a plurality of walls which together define a habitable interior, wherein at least one wall is a reinforced wall capable of spanning a spanning distance of at least 50 feet without underlying support. In some embodiments, reinforced walls comprise one or more reinforcing structures. In some embodiments, the spanning distance is at least 60 feet; in some, at least 70 feet; and in some, at least 80 feet. In a further aspect, a method of building construction comprises the steps of: a) constructing a modular building unit according to the present disclosure at an assembly site; b) transporting the modular building unit to a construction site; and c) installing the modular building unit at the construction site, optionally across a unsupported span of at least 50 feet.