Self-Aligning Connector for Modular Building Installation
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Solution Overview
Problem
Modular building systems face challenges with inventory management and on-site installation due to the complexity and risk of incorrect adaptor usage, as well as the need for additional work to ensure a water-resistant and airtight connection between modules, which can lead to assembly failures or damage.
Innovation Solution
A self-sealing modular building module with self-aligning connectors, featuring a male connector with a hemispherical terminus that can be connected to a female connector with a corresponding aperture, allowing for off-level installation and self-correction, and equipped with sealing gaskets for a secure and watertight joint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If specialized adaptors are used to attach modules, then module connection is enabled, but inventory management complexity increases and risk of incorrect installation arises
Solution Approach 1:
The patent implements universal male and female connectors that can be used across all module connections, eliminating the need for multiple specialized adaptor types. Each module has standardized connectors that work with any opposing module, simplifying inventory to just two connector types while maintaining full connection capability.
Solution Approach 2:
Instead of providing multiple specialized adaptors to fit different scenarios, the patent inverts the approach by making the modules themselves provide the connection interface through integrated male and female connectors. This eliminates the separate adaptor components and their associated complexity.
2Manufacturing precision
If modules are positioned level during installation, then proper alignment is achieved, but open space is required which necessitates additional on-site work for water-resistant and airtight connections
Solution Approach 1:
The module connectors include self-sealing mechanisms that automatically form water-resistant and airtight connections when modules are joined. The self-aligning connectors with hemispherical terminus and corresponding aperture create automatic seals without requiring additional manual sealing work, allowing modules to seal themselves upon connection.
3Ease of operation
If open space between modules is provided, then module installation is facilitated, but additional on-site work is required to form water-resistant and airtight connections
Solution Approach 1:
The connectors incorporate self-sealing features that automatically create water-resistant and airtight seals when modules are connected. This eliminates the need for separate sealing operations and reduces on-site work time, as the sealing function is integrated into the connection process itself.
4Manufacturing precision
If no open space between modules is provided, then assembly precision is improved, but binding occurs between descending module and adjacent module causing assembly failure
Solution Approach 1:
The male connector terminates in a hemispherical shape that fits into a corresponding curved aperture in the female connector. This spherical geometry allows the connector to self-align and pivot during insertion, accommodating slight misalignments and preventing binding while maintaining precise final positioning and reliable connection.
5Manufacturing precision
If no open space between modules is provided, then connection precision is improved, but wear or damage occurs to adjacent modules during installation
Solution Approach 1:
The hemispherical terminus of the male connector allows for smooth, pivoting insertion into the female connector's curved aperture. This spherical interface reduces friction and prevents binding during the connection process, eliminating wear and damage to the module edges and connectors even when modules are positioned closely together.
Data Source
AI summary
A self-aligning module for a self-sealing modular building includes a male connector projecting from a first side of the module to form a cylindrical projection terminated by a terminus having a hemispherical shape, the male connector being dimensioned for being received by a female connector having an aperture dimensioned to receive the terminus and at least a portion of the cylindrical projection so as to permit the module to be connected to the female connector by off-level installation. The module may include a module gasket for self-sealing against an adjacent module.A method of assembling the modular building involves: (a) off-level contacting the terminus to the female connector; and (b) aligning the module and the adjacent module such that the cylindrical projection is received by the female connector. The male connector may be bolted to the female connector, bolted to another male connector, and/or locked by a key-lock system.