Modular Building Construction With Swallowtail Panel Connectors

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Solution Overview

Problem

Existing modular construction systems are complex to manufacture, difficult to transport, and cumbersome to mount, lacking efficient integration of essential supplies like electricity, water, and heating, and do not meet housing norms for temporary structures.

Innovation Solution

A modular construction system using swallowtail connector protrusions and notches on wall panels and vertical columns for toolless assembly, allowing easy transport and rapid mounting, with integrated conduits for utilities and compliance with housing norms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If surface panels are used to cover entire facade with multiple windows and doors, then the housing structure can be quickly assembled, but the panels become difficult to transport through stairways and elevators

Engineering Contradiction:

Improveassembly speedVSAvoidpanel size

Core Design Contradiction:

ProductivityVSLength of moving object

Solution Approach 1:

The patent divides the wall structure into modular components: vertical columns, horizontal beams, and smaller wall panels. These segmented parts can be transported through standard building access (stairways and elevators) while still enabling rapid assembly through standardized swallowtail connector interfaces that join the segments together to form complete walls with windows and doors.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If butterfly shaped tenons are used to lock panels, then the panels can be interconnected, but the tenons become difficult to mount as they must be lifted to a height above the panels

Engineering Contradiction:

Improvepanel connectionVSAvoidmounting difficulty

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

Instead of lifting connectors above panels to engage them (as in the prior art), the patent inverts the connection approach: swallowtail connector protrusions are attached to the panels themselves, and the corresponding notches are provided on the vertical columns and beams. This allows workers to simply slide the panel connectors into the structural element notches at panel level, eliminating the need to lift connectors to heights above the panels.

Inventive Principle:

Principle #13The other way round (Inversion)

3Strength

If complex interlocking portions are used on wall panels, then a rigid housing structure can be formed, but the panels require dedicated manufacturing machines and are complex to produce

Engineering Contradiction:

Improvehousing structure rigidityVSAvoidpanel production complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent separates the structural connection function (provided by simple swallowtail connectors on vertical columns and beams) from the wall panel itself. The wall panels become simpler, flat elements that attach to the structural framework, eliminating the need for complex interlocking portions on the panels and their dedicated manufacturing machines.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The vertical columns and horizontal beams serve multiple functions: they provide the primary structural framework, contain the swallowtail connector notches for assembly, and incorporate vertical channels for utilities. This multi-functionality eliminates the need for separate complex features on individual wall panels, simplifying their manufacture while maintaining structural rigidity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Strength

If non-symmetric wall panels are used, then the housing structure can be rigid, but the panels do not allow fast, dummy proof positioning and connecting

Engineering Contradiction:

Improvestructural rigidityVSAvoidpositioning speed

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent employs asymmetric swallowtail connector geometries (with specific tooth configurations and orientations) that provide both structural rigidity through strong mechanical engagement and dummy-proof positioning. The asymmetric shape allows workers to quickly identify the correct orientation and insertion direction, enabling fast and error-free assembly while maintaining rigid structural connections.

Inventive Principle:

Principle #4Asymmetry

Data Source

PatentEP4179165B1Modular construction system and construction method for a building structure

Publication Date: 2025.09.10 SAAMO BRUSSEL VZW

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Figure 3A~3C

AI summary

A modular construction system based on interconnected parts comprising: - at least one ground ruler (101; 1500; 1510, 1560) having a front side, back side, bottom surface, top surface and lateral sides, wherein the top surface comprises a cut¬ out (102; 1507; 1511, 1512, 1561) adapted to receive a part; - at least one wall panel (110, 111, 112; 1600, 1610, 1620, 1630) having a front side, back side, bottom surface, top surface and lateral sides, wherein each lateral side comprises at least two swallowtail connector protrusions; and - at least one vertical column (120, 121, 122, 123, 124; 1700, 1800, 1810, 1820) comprising parts (401, 402; 1701-1704; 1801-1805; 1811-1816; 1821-1824) glued together to create a vertical channel (403; 1705) for conduits, and having at least one lateral side (400; 1713) comprising two swallowtail connector notches (404, 405; 1708, 1709) adapted to receive the swallowtail connector protrusions of the wall panel (110, 111, 112; 1600, 1610, 1620, 1630).