Prefabricated Floor Panel Assembly for Modular Building Construction

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Solution Overview

Problem

Conventional construction methods are time-consuming and prone to waste and cost overruns due to the linear sequencing of trades and the lack of efficiency in building component installation, particularly in multi-story building projects.

Innovation Solution

The use of prefabricated components, such as floor panels and walls, assembled off-site and assembled on-site to form building units according to a floor plan, which allows for the creation of building units with standardized or mixed sizes and shapes, reducing on-site construction time and waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional construction methods are used with linear sequencing of trades, then each unit can be customized, but construction time increases and waste increases

Engineering Contradiction:
Improvecustomization capabilityVSAvoidconstruction time
Core Design Contradiction:
Adaptability or versatilityVSLoss of time

Solution Approach 1:

The building is divided into standardized modular components (floor panels, wall panels, roof panels) that can be pre-fabricated off-site and assembled on-site. This segmentation enables parallel production of components while maintaining the ability to configure different building types through combination of standard modules.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Building components are pre-fabricated in a controlled factory environment before being transported to the construction site. This preliminary action allows for concurrent manufacturing of multiple components, reducing on-site construction time while maintaining quality standards.

Inventive Principle:
Principle #10Preliminary action

2Adaptability or versatility

If conventional construction methods are used with linear sequencing of trades, then each unit can be customized, but material waste increases

Engineering Contradiction:
Improvecustomization capabilityVSAvoidmaterial waste
Core Design Contradiction:
Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The building is divided into standardized modular components (floor panels, wall panels, roof panels) that can be pre-fabricated off-site and assembled on-site. This segmentation enables parallel production of components while maintaining the ability to configure different building types through combination of standard modules.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Standardized panel dimensions and modular configurations are used to optimize material utilization in manufacturing. By changing the parameters to standardized sizes, material cutting waste is reduced and factory production efficiency is improved while still allowing architectural flexibility through modular arrangement.

Inventive Principle:
Principle #35Parameter changes

3Loss of time

If prefabricated components are used, then construction time is reduced, but storage space requirements increase

Engineering Contradiction:
Improveconstruction timeVSAvoidstorage area
Core Design Contradiction:
Loss of timeVSArea of stationary object

Solution Approach 1:

The building is divided into standardized modular components (floor panels, wall panels, roof panels) that can be pre-fabricated off-site and assembled on-site. This segmentation enables parallel production of components while maintaining the ability to configure different building types through combination of standard modules.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Multiple building components are stacked vertically in three-dimensional storage configurations at the construction site, efficiently utilizing vertical space rather than requiring extensive horizontal storage areas. This dimensional approach allows compact storage of prefabricated panels before assembly.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

4Productivity

If prefabricated components are used, then construction efficiency is improved, but component complexity increases

Engineering Contradiction:
Improveconstruction efficiencyVSAvoidcomponent complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

Standardized panel connections and modular designs are used so that the same basic components can serve multiple functions and be assembled in various configurations. This universality simplifies the complexity by using repeated standard details rather than unique custom components for each building element.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Data Source

PatentUS10487493B2Building design and construction using prefabricated components
Publication Date: 2019.11.26 INNOVATIVE BUILDING TECHNOLOGIES LLC
  • US10487493B2 patent drawing
  • US10487493B2 patent drawing
  • US10487493B2 patent drawing

AI summary

A method of assembling a building unit in accordance with a floor plan of a building using prefabricated components may include installing a first prefabricated floor panel in a first position of the building unit, the first floor panel being selected from a first plurality of prefabricated floor panels having a same first width; installing a second prefabricated floor panel in a second position of the building unit, the second floor panel being selected from a second plurality of prefabricated floor panels having a same second width; and installing a third prefabricated floor panel in a third position of the building unit, the third floor panel being selected from a third plurality of prefabricated floor panels. The floor panels in the third plurality of prefabricated floor panels may have different widths. The third floor panel may be selected such that a sum of the widths of the first, second, and third floor panels corresponds to the total width of the building unit in accordance with the floor plan.