Pre-assembled Wall Panel with Integrated Utility Diverter
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Solution Overview
Problem
The construction industry faces inefficiencies due to the need for skilled tradespeople to travel to multiple construction sites for installing electrical wiring, plumbing, and other utilities in modular construction, increasing labor costs and reducing time efficiencies.
Innovation Solution
Pre-assembled wall panels with integrated utilities such as plumbing and electrical wiring are manufactured off-site, allowing for faster assembly and reducing the requirement for skilled tradespeople on-site, as these panels can be installed vertically and horizontally to provide utilities across multiple stories.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If utilities are installed at construction sites by skilled tradespeople, then installation quality is ensured, but labor costs increase and time efficiency decreases
Solution Approach 1:
The patent applies preliminary action by pre-installing utility components (electrical wiring, plumbing, data lines) into wall panels at an off-site prefabrication facility before the panels are transported to the construction site. This advance preparation eliminates the need for skilled tradespeople to travel to multiple construction sites, reducing labor costs and time inefficiencies while maintaining installation quality through controlled factory conditions
2Adaptability or versatility
If skilled tradespeople travel to multiple construction sites for utility installation, then utilities are installed across different locations, but labor costs increase
Solution Approach 1:
The patent applies segmentation by dividing the building into modular wall panels that are independently prefabricated at an off-site facility. Each panel is equipped with its own integrated utility components, allowing parallel production of multiple panels without requiring skilled tradespeople to travel between sites. This segmentation maintains the ability to install utilities across multiple locations while significantly reducing labor costs through centralized factory production
3Productivity
If utilities are pre-installed in wall panels at an off-site facility, then time efficiency improves, but panel complexity increases
Solution Approach 1:
The patent applies merging by integrating multiple utility systems (electrical wiring, plumbing, data lines) and structural components into a single pre-assembled wall panel. This consolidation allows the entire assembly to be manufactured at an off-site facility with controlled precision, then rapidly installed at the construction site as one unit, improving assembly speed while managing complexity through standardized factory processes
Data Source
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AI summary
An example pre-assembled wall panel may include a panel frame which includes a plurality of studs connected to opposing end members, first and second wall boards connected to opposite first and second sides of the panel frame, a plurality of spacers attached to at least one of the first and second wall boards and configured to support a finish panel in a spaced relation from the at least one of the first and second wall boards; and a pipe disposed between the first and second wall boards and extending between the opposing end members, wherein the pipe includes a pipe diverter, and wherein a free end of the pipe diverter passes through an opening in the first wall board or the second wall board.