Modular Roof Structure With Concealed Connections
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Solution Overview
Problem
Existing modular roofing structures lack efficiency and versatility in assembly, aesthetics, and functionality, particularly in forming various building types and integrating solar performance.
Innovation Solution
A modular post, beam, and arched member system with adjustable vertical and angled members, connectors, and concealed connections that allow for easy assembly and expansion, enabling the creation of diverse structures such as car ports, shelters, and solar-powered buildings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional modular roofing structures use fixed design configurations, then manufacturing and assembly are simplified, but adaptability to different building types and functions is reduced
Solution Approach 1:
The roofing structure is divided into modular units comprising vertical posts, horizontal beams, and arched members that can be independently manufactured and assembled. Each module can be configured in different arrangements to create various building types such as car ports, shelters, and solar-powered structures, thereby achieving adaptability without proportionally increasing overall system complexity
Solution Approach 2:
The patent designs universal connection nodes and standardized interface elements that allow the same basic modular components to serve multiple functions and be assembled into different building configurations. The vertical posts, beams, and arched members can be arranged to create various structural forms and support different roofing applications, eliminating the need for entirely different component sets for each building type
2Ease of operation
If modular roofing structures use exposed connection methods, then assembly is simpler and more straightforward, but aesthetic appearance is compromised
Solution Approach 1:
The connection nodes are designed with nested structures where connecting elements are concealed within housing components. The vertical posts contain internal channels and recesses that accommodate horizontal beams and arched members, hiding the connection mechanisms within the visual form of the posts themselves. This maintains assembly simplicity while achieving clean, aesthetically pleasing exterior surfaces
Solution Approach 2:
Concealing cover elements and decorative caps are introduced as intermediary components that bridge the functional connection nodes and the visible exterior surfaces. These intermediaries maintain the structural connection functionality while providing aesthetically pleasing visual elements that hide the mechanical connection details from view
3Productivity
If traditional roofing structures use numerous fabrication steps and components, then structural integrity can be maximized, but manufacturing efficiency and assembly speed are reduced
Solution Approach 1:
Multiple structural functions are merged into integrated components. The vertical posts combine support, connection, and aesthetic functions in single elements. Connection nodes integrate multiple joining operations into unified assemblies that achieve structural integrity through combined mechanical and geometric interlocking rather than multiple separate fastening steps, thereby reducing assembly operations while maintaining strength
Data Source
AI summary
A post, beam and arched member modular building is shown. The modular building may be formed into any number of different configurations and different structures. The system relies upon a box shape formed from four vertical members, with an arched member extending between each of the adjacent vertical members. The rear vertical members being higher than the front vertical members, with angled members, or rafters extending from the rear vertical members (or a cross-member at the same height thereof) to the front vertical members (or the corresponding arch). In the configuration shown, the angled members or rafters are co-planar. The structure has substantial symmetry and aesthetic design.