Modular Wall Panel Kit with Reversible Attachments
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Solution Overview
Problem
Current modular building structures have limited structural rigidity, require on-site cutting of materials, and suffer from thermal bridges due to inadequate insulation, leading to inefficiencies and waste in construction.
Innovation Solution
A modular building kit with pre-dimensioned components that can be assembled without measuring tools, featuring elongated posts and wall panels with reversible attachments, allowing for tight fitting and insulation between panels to eliminate thermal bridges and enhance structural rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional construction techniques are used with kits, then buildings can be assembled, but structural rigidity is limited and assembly time increases
Solution Approach 1:
The building structure is divided into modular components (wall panels, posts, roof sections) that can be pre-fabricated with precise dimensions and connection features. Each module includes integrated attachment mechanisms that eliminate the need for on-site cutting and fitting, thereby increasing structural rigidity while reducing assembly time through simple connection operations.
Solution Approach 2:
Critical structural elements such as wall panels and posts are pre-fabricated with precise dimensions, pre-drilled holes, and pre-attached insulation materials before reaching the construction site. This preliminary preparation ensures exact fit and optimal structural rigidity while significantly reducing on-site assembly time and eliminating the need for measurement and cutting operations.
2Ease of manufacture
If traditional construction techniques are used, then buildings can be completed, but material waste increases due to cutting
Solution Approach 1:
The building envelope is segmented into standardized wall panels and posts with predetermined dimensions that match the modular grid system. These segments are manufactured to exact specifications, eliminating the need for on-site cutting and minimizing material waste while maintaining construction simplicity through consistent module sizes and connection methods.
Solution Approach 2:
The design adopts fixed dimensional parameters for all structural components based on a modular grid system. Wall panels, posts, and roof sections are manufactured with precise dimensions that eliminate the need for field modifications. This parameter standardization reduces material waste while keeping the construction process simple and systematic.
3Ease of manufacture
If insulation is inserted between internal and external walls attached to studs, then walls can be constructed, but thermal bridges form at stud locations
Solution Approach 1:
The stud framework that creates thermal bridges is extracted from the wall assembly and replaced with continuous insulated wall panels. The insulation material is integrated directly into the wall panel structure, eliminating gaps and thermal bridges at stud locations while maintaining ease of construction through modular panel installation.
Solution Approach 2:
The wall panels are constructed as composite structures combining structural framing material with continuous insulation layers and cladding. This composite design ensures thermal continuity across the entire wall assembly, eliminating thermal bridges while maintaining construction simplicity through pre-fabricated multi-layer panels that integrate multiple functions.
Data Source
AI summary
The disclosure relates to a kit for building an exterior wall of a modular building structure. The kit comprises at least two substantially elongated posts and a wall panel for installing on the at least two posts. The wall panel includes a wall panel first attachment and a wall panel second attachment. The wall panel first and second attachments each includes an L-shaped wall panel attachment linking member, an attachment bracket post attachment portion, a wall panel attachment bracket and an attachment bracket spacing section.