Polygon Panel Frames for Modular Building Assembly
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Solution Overview
Problem
Conventional construction methods, such as wood-frame, brick and mortar, and steel frame construction, are inefficient, costly, and require skilled labor, leading to resource wastage and difficulties in customization and future alterations.
Innovation Solution
The use of pre-fabricated polygon-shaped panel frames with separators and fasteners to create modular building assemblies that provide structural support, allow for easy installation of utilities, and enable quick disassembly and reassembly, eliminating the need for continuous vertical frame supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional wood-frame construction with custom-manufactured framing members is used, then structural support is achieved, but manufacturing complexity and skilled labor requirements increase significantly
Solution Approach 1:
The invention segments the building structure into standardized panel frames (walls, floors, roofs) that can be manufactured independently using consistent processes. Each panel frame is a discrete module with standardized dimensions and connection points, eliminating the need for custom manufacturing of individual framing members while maintaining structural integrity through modular assembly
Solution Approach 2:
The panel frames are designed as universal components that can serve multiple functions across different building types and configurations. The standardized geometry and connection mechanisms allow the same basic panel frame design to be used in walls, floors, and roofs, reducing manufacturing complexity while providing adequate structural support for various applications
2Stability of the object's composition
If conventional construction methods are used, then structural stability is achieved, but construction time and labor costs increase
Solution Approach 1:
The panel frames are pre-assembled and pre-configured offsite before delivery to the construction site. Connection points, utility channels, and structural elements are prepared in advance during manufacturing, allowing for rapid on-site assembly without requiring time-consuming field fabrication or complex coordination of multiple trades
Solution Approach 2:
The construction system enables dynamic adaptation to different building configurations through modular panel frame assemblies. Standardized connection mechanisms allow panels to be quickly reconfigured or repositioned during construction, maintaining structural stability while accelerating the building process compared to fixed conventional methods
3Manufacturing precision
If custom-manufactured framing members are used, then geometric precision is achieved, but material wastage increases
Solution Approach 1:
The design segments the structure into standardized panel frames with optimized dimensions that maximize material utilization. By dividing the building into modular units with consistent geometries, the system eliminates the need for excessive custom cutting and fitting, thereby reducing material wastage while maintaining the required geometric precision for structural integrity
Solution Approach 2:
The invention standardizes key geometric parameters of the panel frames (dimensions, angles, connection point locations) to enable precise manufacturing using consistent processes. This standardization allows for optimized material cutting patterns and reduced scrap, while the controlled parameters ensure that geometric precision requirements are met for structural assembly
4Productivity
If modular construction with prefabricated units is used, then assembly speed is improved, but cost and overhead requirements increase
Solution Approach 1:
The invention segments the building into lightweight panel frames that are easier and less expensive to manufacture and transport than traditional modular units. The panel frames are divided into manageable modules that can be assembled on-site without requiring expensive cranes or heavy lifting equipment, thereby maintaining fast assembly speeds while reducing overhead costs and equipment requirements
Solution Approach 2:
The panel frames are designed as economical, lightweight components that can be manufactured at lower cost compared to permanent modular construction units. The design accepts that individual panels may need replacement or modification over time, allowing for cost-effective manufacturing with simpler materials and processes, thereby reducing overall project costs while maintaining rapid assembly capabilities
Data Source
AI summary
The present invention is to provide assemblies with polygon shaped panel frames, separators and parts for light weight construction that is versatile, rigid, flexible and structurally stable. The assemblies with polygon shaped panel frames, separators and parts for constructing a complete building structure eliminates the need for conventional framing using unitized polygon shaped panel frames with alignment pieces, separators and fastener parts connected together. The assemblies with polygon shaped panel frames, separators and parts comprises of panel frames which are different geometric shapes or polygon parts, including but not limited to circles, ovals, triangles, trapezoids, rectangles, squares, pentagons, hexagons, etc. Panel frames can be hollowed or solid and can be fabricated as pieces of and in itself. Panel frames can be composed of many types of materials including but not limited to wood, metal, polymers, composites, plastics, etc. Two (2) or more panel frames are connected with fasteners utilizing a “link”. Links are parts that create separation between the panel frames and also conjoin other panel frames. Links provide load transfer and can be made of polymers, wood, composites, metal, plastics, etc. The panel frames and links are connected together using fasteners like screws, bolts, nuts, tee-nuts, rivets, rivet nuts, couplers, standoffs, dowels, etc. The panel frames and links are designed to repeat and can provide a building structure with window and doorway openings space and utility space for electrical and plumbing installations. Further, the assemblies can be easily rearranged and reassembled to achieve the desired configuration at low cost, efficient time and minimal labor.