Modular Wall Internal Frame Layout for Fast End-to-End Assembly
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Solution Overview
Problem
Existing modular wall systems face challenges in efficient and cost-effective assembly, particularly in aligning and securing vertical frame members for end-to-end junctions, which complicates the installation process and requires skilled labor.
Innovation Solution
A pre-assembled internal frame design featuring vertically oriented frame members with inverted flanges and recessed fastener receiving portions, allowing for easy alignment and secure fastening of horizontal members, along with height adjusters for vertical adjustments, enabling quick and efficient installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional modular wall systems are used with standard vertical frame members, then the structure is simple and easy to manufacture, but the assembly process is time-consuming and requires skilled labor for alignment and securing
Solution Approach 1:
The frame members are pre-assembled at the manufacturing plant with horizontal members already secured to vertical members using recessed fastener receiving portions. This preliminary assembly eliminates the need for skilled labor during installation, as the pre-assembled units simply need to be connected together on-site, thereby increasing assembly speed without requiring complex field operations
Solution Approach 2:
The wall system is divided into modular pre-assembled frame units that can be manufactured separately and then connected on-site. Each unit consists of vertical and horizontal frame members assembled as a complete module, allowing for rapid deployment while maintaining structural integrity through standardized connection interfaces
2Ease of operation
If vertical frame members are designed with inverted flanges and recessed fastener receiving portions for easy alignment, then the installation becomes simpler and faster, but the manufacturing process becomes more complex
Solution Approach 1:
The invention combines multiple functions into the vertical frame members: the inverted flanges provide both structural support and alignment features, while the recessed fastener receiving portions simultaneously serve as mounting locations and alignment guides for horizontal members. This integration of multiple functions into single components simplifies the overall assembly process despite increased individual component complexity
Solution Approach 2:
The recessed fastener receiving portions are designed to automatically guide and align horizontal frame members during assembly. The self-aligning feature eliminates the need for complex alignment procedures or specialized tools, allowing installers to simply connect components without extensive training or skill
3Loss of time
If pre-assembled internal frames are used for modular walls, then installation time and costs are reduced, but the initial manufacturing complexity increases
Solution Approach 1:
The frames are pre-assembled at the manufacturing plant with all vertical and horizontal members connected using recessed fasteners. This preliminary assembly transfers the complexity from the installation phase to the manufacturing phase, resulting in rapid on-site installation while maintaining standardized, repeatable manufacturing processes that can be efficiently automated
Data Source
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AI summary
A pre-assembled internal frame for a modular wall comprises a pair of vertical frame members. Each first flange of the vertical frame member has a pair of series of vertically arranged mounting openings, and each second flange has a single series. The vertical frame members are oriented to enable the frame to be arranged in an end to end junction with another frame with adjacent vertical frame members thereof abutting. This provides three of the series of vertically arranged openings on each side of the modular wall at the end to end junction. A fastener is positioned in a fastener receiving portion for fastening the horizontal frame member to the vertical frame members. The fastener receiving portions are recessed laterally inwardly from the first and second web sections for avoiding interference between adjacent fasteners when the frame is arranged in the end to end junction with another such frame.