Modular Wall Panels with Pre-installed Electrical Raceways

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Solution Overview

Problem

The construction of healthcare facilities is time-consuming and costly due to the sequential installation of electrical, plumbing, and duct rough-in components, which relies heavily on skilled labor and on-site assembly, and lacks efficient labeling for circuit tracing and maintenance.

Innovation Solution

A modular building system featuring pre-fabricated wall panel units with pre-installed electrical hardware and connectors, along with a modular electrical raceway system that includes independent normal and emergency power tracks, allowing for plug-and-play installation and improved seismic protection, enabling off-site pre-assembly and efficient on-site connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional sequential construction methods are used with on-site assembly, then skilled labor can be utilized for flexible installation, but construction time and costs increase significantly

Engineering Contradiction:

Improveconstruction speedVSAvoidconstruction time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-assembling wall panels, electrical rough-ins, plumbing fixtures, and ductwork in controlled factory environments before delivery to the construction site. This allows multiple trades to work simultaneously on separate components, eliminating sequential on-site dependencies and significantly reducing overall construction time.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The construction system is divided into discrete, modular components including pre-fabricated wall panels with integrated electrical and plumbing assemblies, modular duct sections, and standardized fixtures. This segmentation enables independent fabrication, quality control, and parallel assembly of multiple building systems simultaneously.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If multiple skilled trades are sequenced for on-site installation, then each trade can perform specialized tasks, but the construction process becomes complex and time-consuming

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidconstruction process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges electrical rough-ins, plumbing fixtures, and ductwork assemblies into integrated wall panel units that are pre-assembled in factories. This consolidation reduces the number of separate on-site installation sequences required, as multiple trade components are already coordinated and connected within each modular panel before delivery.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Standardized connection interfaces and coupling mechanisms serve as intermediaries between different modular components. These pre-designed connection points enable rapid assembly of electrical, plumbing, and HVAC systems without requiring complex on-site coordination between multiple skilled trades.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If electrical circuits are installed traditionally on-site, then wiring can be adapted to specific locations, but circuit identification and tracing become difficult for maintenance

Engineering Contradiction:

Improvewiring adaptabilityVSAvoidcircuit identification

Core Design Contradiction:

Adaptability or versatilityVSLoss of information

Solution Approach 1:

The patent implements a color-coded labeling system on electrical components including circuit breakers, conduit markers, and device identifiers. This visual coding scheme enables rapid circuit identification and tracing during maintenance operations, with colors indicating circuit type, priority, and interconnections without requiring detailed documentation review.

Inventive Principle:

Principle #32Color changes

4Ease of manufacture

If conventional construction methods are used, then traditional installation procedures can be followed, but seismic protection for electrical circuits is insufficient

Engineering Contradiction:

Improveinstallation simplicityVSAvoidseismic protection

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent incorporates seismic protection measures during the factory assembly process, including pre-attached seismic bracing, flexible connection elements, and reinforced mounting hardware on all electrical and plumbing components. This beforehand cushioning ensures that critical infrastructure survives seismic events without requiring complex retrofits after construction.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS9972985B1Prefabricated multitrade subassembly building system and methods

Publication Date: 2018.05.15 TANNENBAUM JEROME S

AI summary

A prefabricated multi-trade subassembly building system includes a plurality of plug-and-play modular components that may be constructed and prewired at an offsite location and subsequently shipped to a construction site. The system is particularly useful for building medical diagnosis and/or treatment facilities such as hospitals and clinics. Upon arrival at the construction site, the modular prewired components are assembled and interconnected. The modular components include one or more prewired electrical raceways, prewired wall panel units, and prewired medical headwall units.