Modular Space Frames Using Intersecting Mortise-Tenon Assemblies
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The complexity and high production costs of traditional space frames make them difficult and expensive to produce, especially on a small scale, and they often require specific materials and designs, limiting their scalability and applicability.
Innovation Solution
The development of components with alternating linear struts and inflection areas that can be easily manufactured and assembled into three-dimensional space frames using a method involving intersecting arrays and mortise-tenon structures, allowing for the use of various materials and scalability without redesigning components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional space frame construction methods are used, then high strength is achieved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The space frame is divided into discrete modular components (struts with standardized connection features) that can be manufactured separately and assembled systematically. Each component is a simple extruded profile with standardized ends, allowing mass production through conventional extrusion processes rather than complex fabrication.
Solution Approach 2:
A universal connector design with standardized mortise and tenon features is applied to all struts, allowing the same component geometry to serve multiple structural functions. This universal interface enables different strut configurations to be assembled using the same connection methodology, reducing manufacturing complexity while maintaining structural integrity.
2Strength
If traditional space frame construction methods are used, then structural integrity is maintained, but production cost increases
Solution Approach 1:
By segmenting the structure into standardized extruded components, each piece can be manufactured through cost-effective extrusion processes. The modular nature allows parallel production of multiple components, reducing overall production time and cost while maintaining structural integrity through standardized connection details.
Solution Approach 2:
The design parameters of the struts (cross-sectional geometry, wall thickness, length) can be easily adjusted through extrusion process parameters without changing the fundamental manufacturing method. This flexibility allows cost optimization by selecting appropriate material grades and dimensional parameters for different application requirements.
3Adaptability or versatility
If traditional space frame construction methods are used, then design requirements are met, but scalability is limited
Solution Approach 1:
The standardized connector design serves as a universal interface that can accommodate different strut configurations, sizes, and arrangements. This universality enables scalable design where the same basic component can be used to create structures of varying sizes and complexities by simply adding or removing modules rather than redesigning the entire system.
Solution Approach 2:
The modular component architecture allows the space frame to be scaled by repeating the basic structural unit (strut-cluster assembly). Complex structures are built by systematically arranging these standardized modules, reducing design complexity through pattern repetition while achieving the required scale and adaptability.
4Strength
If traditional space frame construction methods are used, then structural performance is optimized, but assembly time increases
Solution Approach 1:
Pre-fabricated modular components with standardized connection features can be prepared in advance and assembled through simple, repetitive connection operations. This segmentation allows parallel preparation of components and simplifies the assembly process to basic joining operations, significantly increasing assembly speed while maintaining structural performance through standardized connection details.
Solution Approach 2:
The universal connector design enables the same assembly procedure to be used for all joints in the structure, regardless of position or orientation. This standardization of the assembly process reduces the skill level required and speeds up construction, as workers can repeatedly apply the same connection technique without needing to adapt to different joint types.
Data Source
AI summary
A method for producing three-dimensional space frames or truss structures from simpler components and space frames or truss structures produced by the associated method. The various components, which may be made from virtually any material, are shaped in such a way so that they may be fitted together to create a space frame or truss structure. The components may be held together by any available attachment means, or by the interaction of the components themselves. The method and associated components allows for the assembly of three-dimensional space frames or truss structures from planar materials, significantly reducing cost and manufacturing time. These space frames or trusses can then be used as structural members, as the interior load-bearing portions of sandwich panels, or in any situation where high-strength and light weight are desirable.