Pre-tiled Pitched Roof Sections for Modular Assembly
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Solution Overview
Problem
The construction of pitched roof structures on-site is time-consuming and prone to quality control issues due to weather dependence and tile misalignment, leading to increased costs and inferior quality, especially with existing modular systems that struggle to maintain alignment across module joins.
Innovation Solution
A method of creating pre-tiled pitched roof sections by tiling a continuous structure off-site and then separating it into modular sections, ensuring tile alignment and reducing the need for on-site adjustments, with removable junction tiles and ridge filler units for easy assembly and disassembly, allowing for consistent quality and reduced labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pitched roof structures are assembled and tiled on-site, then the roof can be constructed with proper tile alignment, but the process is time-consuming and dependent on weather conditions and skilled labor availability
Solution Approach 1:
The roof structure is tiled in advance at the manufacturing facility before being transported to the building site. This preliminary tiling action ensures proper tile alignment is achieved in a controlled environment, eliminating the need for time-consuming on-site tile laying while maintaining alignment quality.
2Productivity
If pre-assembled roof modules are transported to the building site, then on-site construction time is reduced, but tile misalignment occurs at the joins between modules
Solution Approach 1:
Multiple roof sections are tiled together as a single continuous structure at the manufacturing facility before separation. This merging approach ensures that tiles spanning across what will become module joins are properly aligned, eliminating the misalignment problems that occur when modules are tiled separately and then assembled.
Solution Approach 2:
The continuous tiled roof structure is divided into separable sections at designated join lines. This segmentation allows the roof to be transported in manageable modules while maintaining the integrity of tile alignment, as the tiles were laid continuously before separation.
3Manufacturing precision
If the entire roof structure is pre-assembled and pre-tiled off-site, then quality control is improved and on-site time is reduced, but the size and weight become impractical for transportation
Solution Approach 1:
The roof structure is divided into multiple smaller, separable sections that can be transported individually. This segmentation reduces the weight and size of each transport unit while maintaining the quality benefits of off-site construction, as each section can be properly supported and handled during transportation.
Data Source
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AI summary
A method of making a plurality of pre-tiled pitched roof sections for arrangement on the walls of a building. The method includesbuilding a pitched roof structure having a plurality of separable sections, tiling the pitched roof structure in courses and separating the tiled pitched roof structure into a plurality of separate pre-tiled roof sections.