Modular Wall System with Form-Locking Joints
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Solution Overview
Problem
Existing module systems for building purposes, such as brick structures, face logistical challenges due to the weight and water requirements of traditional bricks and mortars, especially in temporary or hasty construction projects, and lack efficient integration of features like insulation and HVAC technology.
Innovation Solution
A module system comprising thin-walled, hollow basic components with internal spaces for filling with insulation or binding materials, and end blocks with form locking joints for easy assembly without tools or liquid media, allowing for the integration of HVAC technology and reduced waste through use of recycled or biodegradable materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional bricks and mortars are used for wall structures, then the structures are load-bearing and massive, but the weight is considerable and logistical problems arise
Solution Approach 1:
The wall structure is divided into individual modular components (U-shaped elements, end blocks, connection pieces) that can be manufactured separately and assembled on-site. This segmentation allows each component to be optimized for strength while reducing overall material weight and improving logistics.
Solution Approach 2:
The module system combines different materials strategically: thin-walled U-shaped elements provide structural framework, while filler materials (concrete, insulation, sand) provide mass and strength. This composite approach achieves load-bearing capacity with reduced weight compared to traditional solid brick construction.
2Stability of the object's composition
If traditional brick structures are assembled with mortars, then the bricks are bonded together, but water requirements increase logistical complexity
Solution Approach 1:
The invention extracts and eliminates the mortar component entirely from the assembly process. Instead of using water-based mortars for bonding, the system employs mechanical form-locking joints and coupling elements that require no water, directly addressing the logistical complexity of water supply in construction projects.
Solution Approach 2:
The chemical bonding mechanism of mortar is replaced with a mechanical bonding system consisting of form-locking joints, coupling elements, and interlocking geometries. This substitution eliminates the need for water-based adhesives while maintaining structural stability.
3Ease of operation
If LEGO-style blocks with form locking joints are used, then assembly is simplified, but the structures lack sufficient stability without adhesive bonding
Solution Approach 1:
The connection system is segmented into multiple functional elements: form-locking joints for basic connection, coupling elements for reinforcement, and filling materials for final stabilization. This multi-level segmentation allows progressive achievement of both ease of assembly and structural stability.
Solution Approach 2:
The invention merges multiple connection mechanisms (form-locking joints, coupling elements, filling materials) into a unified system that works together to provide both ease of assembly and structural stability, overcoming the limitations of using any single mechanism alone.
4Ease of operation
If U-shaped basic components with coupling elements are used, then assembly without tools is enabled, but the mounting becomes unduly laborious and slow
Solution Approach 1:
Connection pieces and coupling elements are pre-assembled or pre-positioned on the U-shaped elements before final wall assembly. This preliminary action reduces on-site labor and accelerates the overall assembly process while maintaining tool-free operation.
Solution Approach 2:
The assembly process is designed to maintain continuous productive action through standardized interfaces and repetitive modular units. Once the assembly rhythm is established, workers can efficiently repeat the same connection sequence across multiple modules, increasing productivity despite the detailed connection requirements.
5Adaptability or versatility
If hollow internal spaces are filled with insulation or binding materials, then integrated insulation and HVAC capabilities are achieved, but the manufacturing complexity increases
Solution Approach 1:
The hollow internal spaces of the U-shaped elements are designed as multi-functional cavities that can accommodate different filler materials (insulation, concrete, sand) and HVAC components based on project requirements. This universal design approach enables integrated functionality without requiring separate manufacturing processes for each application.
Solution Approach 2:
The filling and integration process is segmented into optional stages: structural filling (concrete/sand) can be done during assembly, while insulation and HVAC components can be added separately. This segmentation allows manufacturers to produce basic modular units without complex integrated systems, reducing manufacturing complexity while maintaining adaptability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates simple, tool-free assembly with reduced logistical burdens and cost-effective production, enabling solid structures with integrated insulation and HVAC capabilities, while minimizing environmental impact through efficient material use and waste reduction.
Implementation Method 1
coupled to each other by means of a form locking joint L1 to coupling arrangements 1b, which are present on each external side U of the basic components 1
Implementation Method 2
filling the internal spaces of the basic components 1 with a filler material such as sand, an insulation material such as polyurethane
Data Source
AI summary
A method and a module system for building purposes by using a module system is provided, said module system including a plurality of mutually equal-sized basic components, which are assembled for a wall structure in one or more vertical planes by installing the same in connection with each other side by side and on top of each other. The wall structure is put together from substantially thin-walled basic components, which are open at ends thereof opposite in a lengthwise direction thereof and have an open internal space, and which are coupled to each other side by side and on top of each other with connection pieces capable of being connected with a first form locking joint to lengthwise coupling arrangements present on each external side thereof. The basic components are coupled to each other with an end block interconnecting the basic components by the opposite ends thereof.