Modular Wall System With Adjustable Stud Assemblies
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Solution Overview
Problem
Construction projects often result in material wastage due to over-purchasing and inefficient site management, leading to increased costs and environmental impact, while traditional construction methods lack modularity and adjustability.
Innovation Solution
A digitized wall system comprising pre-formed components such as stud assemblies, bracket assemblies, leveler assemblies, and hanger assemblies, which are precisely manufactured and assembled using web brackets, threaded rods, and adjustable connectors to facilitate efficient installation, adjustability, and reduced waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional construction methods are used, then construction can be completed with conventional materials and processes, but material wastage increases and construction efficiency decreases
Solution Approach 1:
The wall system is divided into discrete modular components including stud assemblies, track assemblies, and panel assemblies that can be manufactured separately and assembled on-site. This segmentation enables precise material usage planning and reduces waste by only installing the exact components needed for each specific installation scenario.
Solution Approach 2:
Wall components are pre-assembled and pre-configured in controlled manufacturing environments before delivery to construction sites. Stud assemblies are pre-formed with tracks and connectors attached, and panels are pre-cut to specific dimensions, eliminating on-site material cutting and reduction waste while improving installation speed.
2Adaptability or versatility
If traditional construction methods are used, then construction processes are simple and straightforward, but modularity and adjustability are limited
Solution Approach 1:
The wall system employs universal connectors and standardized interface designs that allow the same basic components to serve multiple functions and accommodate various wall configurations. Track assemblies can be adapted for different panel types and sizes, and connectors can join different component types, providing versatility without requiring entirely different systems for each application.
Solution Approach 2:
The wall system incorporates adjustable and reconfigurable elements that allow modifications after installation. Panels can be removed and repositioned, studs can be reconfigured, and the modular design enables easy adaptation to changing spatial requirements, providing dynamic adaptability while maintaining a relatively simple base structure.
3Productivity
If pre-formed manufactured components are used, then installation speed and efficiency improve, but component complexity and manufacturing requirements increase
Solution Approach 1:
Complex wall systems are broken down into standardized modular components that can be manufactured using automated processes. Each component (stud assembly, track assembly, panel assembly) has defined interfaces and connection points, allowing for efficient automated manufacturing while keeping individual component complexity manageable through standardization.
Data Source
AI summary
A wall system includes at least one of a stud assembly, a top connector assembly, and a leveler assembly. The stud assembly is defined by a first and second upright that are attached by at least one web bracket. The web bracket includes a main body with extension arms on opposing sides. A notch is located at or near a free end of each extension arm. The notches are to be removably inserted over an edge of a respective aperture located on each of the first and second uprights. The top connector assembly includes a holder member to effectively raise and lower a top portion of the stud assembly. The leveler assembly includes a threaded rod to effectively raise and lower the first and second uprights relative to a base.