Prefabricated Wall Panel Rail Connections for Rapid Foundation Assembly
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Solution Overview
Problem
Existing construction technologies face challenges such as reliance on skilled labor, heavy machinery, project delays, material waste, and lack of scalability, with prefabricated building modules needing improved components to withstand loads and environmental changes, and robust connectors for seamless integration.
Innovation Solution
A modular building system using prefabricated wall, floor, and roof panels with Light Gauge Steel (LGS) frames, mechanical connectors, and multi-layered construction to ensure structural integrity, weather resistance, and easy assembly, featuring male-female connectors for panel connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional build-on-site approaches are used, then construction can be customized, but skilled workforce and heavy machinery are required, leading to project delays and high costs
Solution Approach 1:
The building is divided into modular components (walls, floors, roofs) that are pre-assembled in factories and then transported to the construction site for quick assembly, eliminating the need for lengthy on-site construction processes
Solution Approach 2:
Building modules are pre-assembled and prepared in factories before being transported to the construction site, allowing the actual construction process to be completed rapidly through simple on-site assembly operations
2Productivity
If prefabricated building modules are used, then assembly is rapid and efficient, but robust connectors are needed to withstand loads and environmental changes
Solution Approach 1:
Multiple connection functions (mechanical attachment, sealing, structural reinforcement) are merged into integrated male-female connector systems that provide both rapid assembly and long-term reliability under various loads and environmental conditions
3Ease of operation
If standardized connectors are used for panel connections, then assembly is simplified and panels can be adjusted or replaced, but connection robustness must not be compromised
Solution Approach 1:
The connector system is designed to be dynamically adjustable during assembly and maintenance, allowing panels to be easily installed, removed, or replaced while maintaining full structural strength through the male-female connection mechanism
Data Source
AI summary
A modular building system allows for quickly and easily erecting prefabricated wall panels on a building foundation at a construction site. The system allows for manufacturing and installing, at a high level, complete budding components, using steps that are highly repeatable and scalable, resulting in construction that is quick and efficient, and easily performed at many types and locations of construction sites. A system in accordance with the invention comprises a wall panel, a floor panel and a roof panel. The wall panel comprises a horizontal member supported along a bottom horizontal edge, and a plurality of vertical studs integral to the horizontal member and extending vertically downward from the horizontal member. A floor panel comprises a rail disposed rigidly fixed to the foundation and defining an enclosure to receive the plurality of vertical studs of the wall panel to thereby vertically position the wall panel upon the foundation.