OpenC Beams for Modular Construction Without Welding
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Solution Overview
Problem
The construction industry faces challenges in building inexpensive, lightweight modular structures quickly and efficiently, as traditional methods using heavy gauge steel require time-consuming and hazardous welding processes, resulting in high costs and waste.
Innovation Solution
The use of openC profile beams with vertical web members, horizontal flanges, and upper vertical tabs to form a base frame, allowing for the assembly of structures without welding by securing vertical posts through cutouts in the beams, which also serve as a structural support for affixing light gauge steel panels, reducing material weight and construction time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding techniques are used to join heavy gauge steel panels and beams, then structural strength is ensured, but construction time increases and welding hazards arise
Solution Approach 1:
The patent replaces the welding process (thermal/chemical joining) with a mechanical fastening system using specialized connectors that join steel components without welding, thereby eliminating welding time and hazards while maintaining structural integrity
Solution Approach 2:
The steel structure is divided into modular prefabricated sections that are transported and assembled on-site using mechanical connectors, allowing for faster construction compared to traditional welded construction methods
2Strength
If heavy gauge steel is used to construct modular structures, then structural strength is maintained, but transportation cost and weight increase
Solution Approach 1:
The patent changes the gauge (thickness) parameter of the steel panels from heavy to light gauge, reducing the weight and transportation cost while the specialized mechanical connectors compensate for the reduced material thickness to maintain structural strength
3Strength
If welding processes are used for assembly, then joint strength is achieved, but safety hazards and specialized labor requirements increase
Solution Approach 1:
The patent substitutes the welding process with mechanical fastening connectors that join steel components without producing heat, sparks, or smoke, thereby eliminating welding-related safety hazards while achieving equivalent joint strength through the mechanical connection system
4Adaptability or versatility
If traditional site-built construction methods are used, then customization is possible, but construction time and cost increase significantly
Solution Approach 1:
The patent divides the building into modular prefabricated sections that can be customized in the factory environment and then rapidly assembled on-site, combining the customization benefits of factory construction with the speed of modular assembly
Solution Approach 2:
The patent performs all customization, fabrication, and assembly operations in a controlled factory environment before delivery to the site, where only final assembly is required, thereby maximizing construction speed while maintaining customization capability
Data Source
AI summary
Described is a method and apparatus for constructing light-weight, modular structures using special openC beams as a top and a bottom frame. Each openC beam comprises a vertical web member, a horizontal top flange extending perpendicularly in a first direction from the vertical web member, a horizontal bottom flange extending perpendicularly in the first direction and substantially parallel with the horizontal top flange and a upper vertical tab extending substantially perpendicularly from a distal edge of the horizontal top flange away from the horizontal bottom flange. Vertical posts are installed in one or more cutouts in the horizontal top flange of each openC beam and a planar surface of each of the vertical posts rests against the horizontal top flange for added support.