Reusable Modular Frame System for Rapid Wall Construction
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Solution Overview
Problem
Traditional building systems lack flexibility for modular construction, are inefficient, costly, and vulnerable to insulation issues, pests, and structural weaknesses.
Innovation Solution
A building system utilizing a collapsible, modular framing system with multiple layers such as wire mesh, rigid foam board, concrete, and sheathing, allowing for efficient, cost-effective, and structurally sound construction that is hurricane-resistant, termite-proof, and highly insulated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional permanently installed frame systems are used, then structural strength is maintained, but construction efficiency is low and cost is high
Solution Approach 1:
The building system is divided into modular components including collapsible frames, pre-cut insulation panels, and standardized wall sections. These modular units can be manufactured off-site and assembled quickly on-site, dramatically improving construction efficiency while maintaining structural integrity through standardized connection methods
Solution Approach 2:
The frame system transitions from traditional permanent installation to a collapsible and reusable design. The frames can be disassembled, transported, and reassembled for multiple building projects, transforming the static construction process into a dynamic, reusable system that improves productivity across multiple builds
2Reliability
If traditional construction systems are used, then basic structure is achieved, but insulation performance is poor
Solution Approach 1:
Insulation panels are pre-cut to exact dimensions and pre-installed within the modular wall sections during manufacturing. This preliminary action ensures optimal insulation placement and performance before the structure is assembled on-site, eliminating the need for complex field installation procedures
Solution Approach 2:
The system combines multiple materials including rigid foam insulation boards, wire mesh, concrete or stucco exterior layers, and weather-resistant barriers into composite wall assemblies. This multi-material approach achieves superior insulation performance while the modular pre-assembly keeps the construction process manageable
3Object-affected harmful factors
If traditional construction methods are used, then basic protection is provided, but resistance to pests and environmental factors is insufficient
Solution Approach 1:
Different materials are strategically placed in specific locations to address local threats: concrete or stucco cladding provides termite-proof exterior surfaces, wire mesh reinforces vulnerable areas, and sealed joints prevent pest infiltration. This localized application of protective materials provides comprehensive pest resistance without requiring complete redesign of the entire manufacturing process
4Loss of time
If reusable collapsible frames are implemented, then construction cost and time are reduced, but structural integrity must be maintained
Solution Approach 1:
The collapsible frame is segmented into standardized modular sections with uniform connection points and reinforcement locations. This segmentation allows the frames to be quickly assembled and disassembled while ensuring that structural reinforcement is consistently applied at all critical joints, maintaining integrity despite the reusable nature of the system
Data Source
AI summary
A building system and method of using the same may include forming a modular, collapsible, reusable frame and applying at least one sheathing layer on the modular, collapsible, reusable frame. The system and method may include applying at least one mesh layer on the at least one sheathing layer; applying at least one concrete layer on the at least one mesh layer; curing the at least one concrete layer; and removing the modular, collapsible, reusable frame. The system and method may form at least one continuous wall and roof portion to make up a monolithic structure defining an interior cavity.