Pre-Assembled Wall Frames for Fast Modular Junction Assembly
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Solution Overview
Problem
Existing modular wall systems require complex on-site assembly, which is time-consuming and often requires skilled labor, and do not allow for easy integration of functional components or modifications post-installation.
Innovation Solution
A pre-assembled internal frame system for modular walls, featuring a stepped configuration of vertical frame members with inverted flanges and horizontal connectors, allowing for efficient end-to-end junctions and easy mounting of wall panels and accessories, with optional height adjusters for alignment and fastener recesses to avoid interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If modular wall systems use traditional assembly methods, then structural integrity is maintained, but installation time increases and skilled labor is required
Solution Approach 1:
The frame members are pre-assembled with mounting openings and flanges configured in specific orientations before shipment. This preliminary configuration eliminates the need for complex on-site assembly operations, allowing workers to simply position and secure the pre-configured frames rather than performing complex assembly procedures during installation
Solution Approach 2:
The wall system is divided into modular frame sections that can be independently manufactured, shipped, and assembled. Each frame member is segmented with specific functional zones (mounting openings, flanges, web sections) that can be independently configured and combined, simplifying the overall assembly process while maintaining structural integrity
2Adaptability or versatility
If traditional wall systems are installed, then structural stability is achieved, but post-installation modifications become difficult
Solution Approach 1:
The frame system incorporates adjustable mounting openings and reconfigurable flange configurations that allow the structure to adapt after installation. The mounting openings can accommodate different panel types and configurations, enabling post-installation modifications without requiring structural changes or specialized skills
Solution Approach 2:
The frame members are designed with universal mounting features that can accommodate various wall panels, accessories, and functional components. The standardized mounting openings and flange configurations allow the same frame structure to serve multiple functions and support different configurations over time
3Ease of manufacture
If pre-assembled frames are used, then installation cost decreases, but manufacturing complexity increases
Solution Approach 1:
The frame members utilize asymmetric flange configurations where the first and second flanges extend in different directions with different mounting opening patterns. This asymmetric design allows each frame member to have a unique orientation and function, simplifying the assembly process by eliminating the need for complex alignment procedures while accommodating the pre-assembled complexity through standardized asymmetric features
Data Source
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.