Modular Unit Connectors With Sliding Alignment and Rigid Interlock
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Solution Overview
Problem
The challenge in modular construction is aligning and rigidly connecting pre-fabricated building units to resist separation forces while allowing precise alignment for exterior cladding, which is labor-intensive and requires multiple fasteners.
Innovation Solution
A connector system with retention clips and alignment pegs/slots that interlock modular units vertically and laterally, using serrations for enhanced engagement, to resist movement and allow precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple different fasteners are used to secure modular units and cladding, then the connection strength and alignment precision are improved, but the device complexity and labor intensity increase
Solution Approach 1:
The connector integrates multiple functions into a single unified component: alignment features (guide pins, slots), retention mechanisms (serrations, interlocking surfaces), and attachment points for both modular units and cladding are combined into one connector assembly, eliminating the need for separate fasteners for each function
Solution Approach 2:
The connector is designed as a multi-functional component that simultaneously provides alignment, rigid connection, and cladding attachment capabilities, allowing a single component type to replace multiple specialized fasteners in the assembly process
2Measurement precision
If multiple different fasteners are used to secure modular units and cladding, then the alignment precision is improved, but the labor intensity and assembly time increase
Solution Approach 1:
The connector incorporates pre-configured alignment features (guide pins, alignment slots, tapered surfaces) that automatically position modular units and cladding with precise alignment during the initial insertion phase, eliminating the need for subsequent adjustment operations
Solution Approach 2:
Alignment and retention functions are merged into a single connector operation, allowing workers to achieve both precise alignment and secure connection in one assembly action rather than requiring separate operations with multiple fastener types
3Strength
If a rigid connector is used to securely attach modular units, then the resistance to separation forces is improved, but the ability to allow precise alignment for cladding decreases
Solution Approach 1:
The connector incorporates dynamic alignment features such as tapered surfaces and adjustable components that allow the rigid structure to adapt during assembly, enabling precise positioning of cladding while maintaining rigid connection strength once assembled
Solution Approach 2:
The connector is divided into functional segments: rigid connection elements for resisting separation forces, and separate alignment features (slots, guide pins, adjustable components) that provide flexibility during the alignment phase without compromising the strength of the final connection
Data Source
AI summary
A connector system for interconnecting vertically adjacent and/or laterally adjacent modular units of a building constructed from such modular units assembled rigidly together includes connectors that are rigidly attached to the modular units. These connectors are able to rigidly interlock with each other so that, when the connectors of adjacent modular units are interlocked with each other, the adjacent modular units are also rigidly attached to each other. The connectors include sliding alignment features that ensure that resist lateral displacement of laterally adjacent modular units and also ensure proper alignment of vertically-engaging retention features that resist vertical displacement of vertically adjacent modular units.