Building module and manufacturing technique thereof

Abstract

The invention relates to a building module for constructing a structure. The building module comprises a fabric sheet, a filler material and a holding device. The fabric sheet is wrapped around the filler material to form a folded portion covering the filler material, wherein the edges of the wrapped folded portion are held in place by the holding device. The wrapping can be filled continuously from above, enabling the building module to be manufactured in a continuous and simplified manner without the need for a series of difficult, labor-intensive steps. As a result, the structure can be quickly constructed in a cost-effective manner.

Description

[0001] Priority details This application claims priority to 202141003403, filed in India on January 25, 2021, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This invention relates generally to the field of building construction. More specifically, this invention relates to building materials and building construction methods. Background Technology

[0003] Generally speaking, construction is costly, labor-intensive, and time-consuming. Therefore, there is a need for more efficient, less labor-intensive processes, as well as cheaper building materials and methods.

[0004] Traditionally, sandbags have been used to construct certain structures, but these are usually temporary. Using sandbags also has drawbacks. First, sandbags have low tensile strength, which is why any structure made of sandbags is often used for unimportant structures. Second, sandbags tend to age, making them impractical for long-term structures.

[0005] An advanced method for constructing structures involves using "conventional bags combined with barbed wire," as disclosed in U.S. Patent No. 5,934,027. This method typically involves filling standard-sized bags from one end, laying them horizontally, and compacting them. The filler is often not just sand but can be a more cohesive compound. Sometimes cement or lime is used to stabilize the material. Sometimes the bags are open-ended fabric tubes with folds at each end for holding soil. The method also discloses the use of long bags. Sometimes, multiple strands of barbed wire are used between the layers to provide tensile strength and shear resistance. Before and after this method, sandbags and similar techniques have been used to construct dams, dikes, fortifications, retaining walls, drainage systems, and other temporary structures. This advancement has enabled the development of techniques for constructing interior-scale buildings, particularly walls, vaults, domes, arches, and domes. This methodology has limitations, namely the inability to make the bags used in them very long and continuous. Even if the bags are longer in some way, it is difficult to fill them uniformly, and the longer length makes the process of filling and solidifying the individual layers require more manpower. This limitation makes the manufacturing process difficult, error-prone, and time-consuming.

[0006] Therefore, there is a need for a technology that can help make construction faster, easier, and cheaper. Summary of the Invention

[0007] This invention relates to a building module for constructing structures, comprising a fabric sheet, a filling material, and a retaining device. The fabric sheet wraps around the filling material to form a folded portion covering the filling material, wherein the edges of the wrapped folded portion are held in place by the retaining device. In fact, these wrappings can be continuously filled from above to create building modules that are otherwise functionally similar to existing technologies, meaning that the construction process can be continuous and simple, without requiring a series of difficult, labor-intensive steps. This enables the rapid construction of structures in a cost-effective manner.

[0008] According to one embodiment of the building module, the fabric sheet is made of synthetic materials, natural fiber materials, or combinations thereof. This fabric sheet extends the lifespan of the building module and enhances the tensile strength and adhesion of the filling material, thereby better supporting the structure using the fabric sheet.

[0009] According to another embodiment of the building module, the filler material is a composite of at least one or a combination of sand, silt, clay, gravel, other types of soil materials, organic materials, recycled waste, and adhesives. Various combinations of filler materials are intended to achieve different purposes. Clay and other adhesives are useful because they bind particles together, thereby improving additional adhesion. Other aggregates (silt, sand, gravel) prevent the clay from overreacting (expanding under wet conditions and shrinking when dry). Sand and gravel also improve compressive strength. Cement and lime improve long-lasting waterproof adhesion. Organic materials are generally not used in construction, except as adhesives or fibers to improve tensile strength. On the other hand, organic materials can be used for various purposes, such as in the manufacture of plantations and retaining walls, where the filler is intended to enable plant growth.

[0010] According to yet another embodiment of the building module, the building module includes an adhesive. The adhesive includes at least one or a combination of lime, clay, cement, protein, plaster, fiber, or glue.

[0011] According to one embodiment of the building module, the internal filling material is compressed or compacted. This helps to stabilize the building module, thereby further stabilizing the structure using the building module.

[0012] According to another embodiment of the building module, the fabric sheet has edges folded upwards and covering the filling material, with one edge of the fabric overlapping the other. This method of manufacturing the building module should help to make it as long (continuous) as possible, allowing it to be filled from above, and making it easier to produce using continuous mechanical processes.

[0013] According to yet another embodiment of the building module, the retaining device is at least one of the following: a stitching device, an adhesive, a nailing device, or a mass applied to the module by subsequent building modules, or a combination thereof. The stitching and nailing devices are secured to the wrapping and penetrate both layers. In the case of adhesive, the adhesive is applied between the two layers of the wrapping. This retaining device allows construction workers to utilize a full range of skills and provides a simpler method for completing building modules more quickly.

[0014] According to one embodiment of the building module, when it is necessary to extend the building module beyond the cut length of the fabric sheet, additional fabric sheets can be added, allowing one end of the first fabric sheet and the opening of the second fabric sheet to be wrapped together. Both the first and second fabric sheets are wrapped around the filling material, and at least one edge of the wrapping is held by a retaining device. This embodiment facilitates the expansion of the building module so that the module is not limited by the length of the fabric sheet.

[0015] According to yet another embodiment of the building module, a fabric sheet is wrapped around a filling material in a spiral configuration, such that a fold is formed around the filling material around each spiral turn, and the edges of the wrapped folds overlap substantially along each consecutive spiral turn. The folds extend obliquely relative to the axis of the building module, the overlapping edges extend obliquely relative to the axis of the building module, and the retaining device extends obliquely relative to the axis of the fabric sheet and the overlapping edges.

[0016] Another aspect of the invention relates to a method of manufacturing a building module, the method comprising the following steps: Step 1, laying a fabric sheet on a previous layer or base made of the building module. Step 2, placing a composite filler material in the shape of a container, wherein the container has an opening at the bottom. Step 3, compressing the filler material from the top using a compression device. Step 4, wrapping the fabric sheet upwards and covering the compressed material by folding one side of the fabric sheet along its length and overlaying the other side, and similarly folding the layers at the very end, once all layers are completed. Step 5, providing a retaining device to securely hold the wrapping of the fabric sheet. The method can be implemented manually, semi-mechanized, or fully mechanized using standard templates or custom-made machines.

[0017] Another aspect of the invention relates to an apparatus for manufacturing building modules. The apparatus includes a filling device and a folding device. The filling device includes a top portion having a top opening and a bottom portion having a bottom opening, such that a composite filling material is filled through the top opening and through the bottom opening onto a fabric sheet. Once the filling material is in place on the fabric sheet, the folding device folds the edges of the fabric sheet to overlap each other. This apparatus helps to mechanize the process of manufacturing building modules, which facilitates faster and more stable module construction.

[0018] According to one embodiment of the device, the folding device has two walls, allowing the filling device to slide between the walls of the folding device, leaving a gap through which the side of the fabric sheet can pass. This embodiment further provides an efficient mechanism for performing the filling of the filler material and the folding of the sheet almost simultaneously, thereby further automating the process and reducing the time required to manufacture building modules. This makes it easier to handle longer fabric sheets, thus making the manufacture of building modules less cumbersome.

[0019] According to another embodiment of the device, the wall of the folding device can slide on the preceding building module or base. This facilitates easy placement of the device on the preceding building module.

[0020] According to yet another embodiment of the device, the device includes one or more pairs of guides connected to the walls of the folding device, enabling the device to be easily placed directly onto the preceding building module or base. The guides further simplify the process of placing the device directly onto the preceding building module.

[0021] According to one embodiment of the device, the folding mechanism includes two flanges such that when a fabric sheet is placed into the device, the side edges of the fabric sheet are functionally engaged with each flange. The front portions of the flanges are unfolded to allow the fabric sheet to be unfolded. In the middle section, the flanges are bent upwards (but still engaged with the fabric sheet) to form a shape that receives and accommodates filler material and allows for compaction. The rear sections of the flanges, still functionally engaged with the edges of the fabric sheet, are folded again to become substantially parallel to each other, completing the folding of the fabric sheet onto the filler material. This flange enhances the automation of folding the edges of the fabric sheet, so the process can be carried out without human intervention. It makes the process of manufacturing building modules more mechanized.

[0022] According to another embodiment of the device, the device includes a compression device that compresses the filler material once it has been placed on the fabric sheet by the filling device. The compression device mechanizes the step of compressing the filler material, which further reduces the need for manual intervention, thereby making the process of building the module more continuous, automated, and rapid.

[0023] According to yet another embodiment of the device, the compression device includes one or more compression rollers for compressing the filling material from above when it is placed on the fabric sheet by the filling device. The rollers are used to compress the filling material by applying pressure to the rollers and rolling over them; a simple mechanism for compressing the filling compound.

[0024] In other embodiments of the device, the compression device includes one or more vibratory compactors for compressing the filler material as it is placed on the fabric sheet by the filling device. Vibratory compactors are lighter and more powerful, yet are a better way to compress filler material.

[0025] According to yet another embodiment of the device, the device includes a retaining device that seals the package once the folded ends of the fabric sheet overlap each other to form a wrap. The seal is achieved using adhesives, staples, or sewing devices, or combinations thereof. The sewing and staples penetrate the two folded portions of the wrap. Adhesive is applied between the folded portions of the wrap. This embodiment provides various options for the retaining device that can be used according to the specific user's requirements or application.

[0026] According to one embodiment of the device, the pinning mechanism includes a pinning roller with a groove that allows pins or spikes of long barbed wire to pass through, pierce the fabric layer and embed the pins or spikes, but still protrude enough to hold subsequent building modules in place.

[0027] According to another embodiment of the device, the pinning device is mounted in tracks on the edges of two unfolded flanges, thereby embedding the pins or spikes of the barbed wire into the edges of the fabric sheet, thus effectively holding and guiding the fabric sheet. In the front portion, the flanges unfold to allow the fabric to be laid out; in the middle portion, the flanges are bent upward to allow the receiving and compacting of filler material; in the rear portion, the flanges fold over each other to become substantially parallel, thus completing the fold, and as the device advances, the pins or barbs are finally embedded into the opposite sides of the fabric sheet.

[0028] According to yet another embodiment of the device, the device includes one or more reels that hold the pinning mechanism or barbed wire and are functionally coupled to the pinning rollers such that, as the device moves, the reels supply pins or barbed wire to be continuously attached to the fabric sheet via the rollers.

[0029] According to one embodiment of the device, the device includes a sheet holder that holds a sheet of fabric and is functionally coupled to a pinning roller, such that when the device moves, the sheet holder passes over the sheet of fabric to reach the pinning roller. Attached Figure Description

[0030] Embodiments of the present invention will now be described with reference to the accompanying drawings, wherein... Figure 1 A cross-sectional view of a set of building modules placed overlapping each other to form a structure is shown.

[0031] Figure 2 A cross-sectional view is shown of a group of barbed building modules placed overlapping each other to form a structure.

[0032] Figure 3 A diagram illustrating a manual method for manufacturing building modules.

[0033] Figure 4 This shows a semi-automated device used to manufacture building modules.

[0034] Figure 5 The diagram shows a fully mechanized device for manufacturing building modules.

[0035] Figure 6 The diagram shows a fully mechanized device for manufacturing building modules, wherein the holding device is configured as barbed wire laid by two rollers.

[0036] Figure 7 Another embodiment of the building module is shown, in which fabric is wrapped around the filling material in a spiral configuration.

[0037] List of icon numbers 1 building module 2. Fabric sheets 3. Filling material 4. Holding device 5. The edge of the package 6. Barbed wire 7 pins 8. Containers, filling devices 9. Compression device 10 Equipment 11 Folding device The walls of folding devices 12A and 12b 13 Guiding Devices 14a, 14b flanges 15 compression rollers 16. Couplings for external propulsion mechanisms 17. Stapling roller 18. Grooves of the staple roller 19 scrolls 20 Sheet Retainers 21 Pin-driven roller Detailed Implementation To aid in understanding the principles of the invention, reference will now be made to the embodiments shown in the accompanying drawings, and they will be described using specific language. However, it should be understood that this is not intended to limit the scope of the invention. Such changes and further modifications in the illustrated systems, as well as such further applications of the principles of the invention that would normally occur to those skilled in the art, will be interpreted as being within the scope of the invention.

[0038] Those skilled in the art will understand that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to limit it.

[0039] The terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, such that a process or method that includes a series of steps includes not only those steps but may include other steps not expressly listed or steps inherent to such a process or method. Similarly, without further constraints, “comprising…” following one or more subsystems, elements, structures, or components does not exclude the presence of other subsystems, elements, structures, components, additional subsystems, additional elements, additional structures, or additional components. The phrases “in one embodiment,” “in another embodiment,” and similar language appearing throughout this specification may refer to the same embodiment but are not necessarily all of the same embodiment.

[0040] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The systems, methods, and examples provided herein are for illustrative purposes only and are not intended to be limiting.

[0041] In the proposed technique of this invention, the sides of a fabric sheet are folded inward and held beneath the subsequent layer to create "wraps" rather than bags. These wraps are the basic building modules used to construct any type of structure. These wraps may be secured together with multi-strand barbed wire, pins, U-shaped nails, stakes, etc., or simply held in place by the pressure of subsequent layers. This technique allows for infinitely long, even continuous, individual layers, whereas previously, bags had to be uniformly filled from one or more open ends, thus practically limiting their potential length. This technique enables continuous, easier, and more uniform in-situ filling, resulting in faster, cheaper, and better construction. This new technique has all the beneficial effects of existing technologies without the frustration of their process. Importantly, this technique makes automation and mechanization much easier, as it facilitates a linear, continuous process using machines and simple forms of movement. It is worth noting that existing technologies do not support this mechanization because it is difficult to uniformly fill the distal and middle portions of the bag. Furthermore, the bag must be rolled up in a certain way for filling and unfolded as filling progresses. This imposes practical limitations on the length of individual bags / arch wedges. The proposed technology will not have the same problem.

[0042] Figure 1 and Figure 2 A cross-sectional view of an exemplary building module 1 placed overlapping each other is shown. Figure 2 Building module 1 also has barbed wire, used to nail the building modules downwards, thus securely sealing them and binding the modules together to provide strength to the structure. Figure 1 In the middle, building module 1 then applies pressure to building module 1 below it to provide resistance to hold the folded portion in place, thereby keeping the building module in a wrapped state. This can be used... Figure 1 or Figure 2 Any of the exemplary modules in the exemplary modules, however, as Figure 2 The barbed building module 1 shown has clear advantages because the barbs not only keep the wrapping in place, but also connect the individual building modules 1 together, and can also be used to functionally attach fabric sheets to manufacturing equipment.

[0043] These building modules 1 are made of fabric sheets 2, which are wrapped around the filling material 3 to form folded portions covering the filling material 3, and the edges 5 of the wrapped folded portions are further held by retaining devices 4. Figure 1 The retaining device 4 in the exemplary building module 1 is held in place by pressure applied by the subsequent building module 1. Figure 2 In the exemplary embodiment, barbed wire 6 is used.

[0044] The fabric sheet 2 has an edge 5 that is folded upwards and covers the filling material, with one edge of the fabric overlapping the other. Furthermore, the internal filling material 3 is compressed or compacted to stabilize the building module 1.

[0045] Fabric sheets can be made of synthetic or natural fibers. Composites of synthetic and natural fibers can even be used. Synthetic materials can be any plastic, polyethylene, or synthetic fibers such as fiberglass or metal wire. Natural fibers are preferred when it is necessary to return the structure to the soil in an environmentally friendly manner. A good example of a natural fiber material is burlap (linen / burlap). After coating, it becomes very durable and will decompose into the soil if not coated or if the coating is damaged, which is very useful for temporary structures such as formwork, revetments, or dams. It is worth noting that any other type of fabric material can also be used; however, the material used should have tensile strength.

[0046] The retaining device 4 can be a sewing device or adhesive, or a stapler, or another building module that retains it on the module, and any combination of retaining devices 4 can be used to further enhance the retaining ability of the wrap. The sewing and stapler devices are secured to the wrap and penetrate both layers, such as... Figure 2 As shown in the diagram, the barbed wire is applied between the two layers of the wrapping to bond them together. Adhesive can also be used between the individual layers / modules / arch wedges.

[0047] The filler material can be sand, silt, clay, gravel, other types of soil materials, organic materials, recycled waste, adhesives, and any combination of these types of filler materials. In one exemplary embodiment, for walls, an ideal formulation is 25% sand, 25% clay, 25% silt, and 25% gravel. In some other embodiments, a mixture including 10% cement can be used for filler material 3. It is worth noting that each filler material has its own practicality and advantages, which will be further mentioned below. Clay, glue, protein, lime, fiber, and cement bind the particles together, thus increasing adhesion. Other aggregates (silt, sand, gravel) prevent the clay from overreacting (expanding under wet conditions and shrinking when dry). Sand and gravel increase compressive strength. Cement and lime improve long-term waterproof adhesion. Organic materials should be avoided unless the structure is temporary, but organic materials help increase tensile strength; for example, fibers (straw, chaff, shredded fabric) have been used in the construction of earthen buildings since ancient times.

[0048] Binders can be lime, clay, cement, protein, gypsum, fiber, glue, or any combination of these. Binders achieve long-lasting adhesion. When the binder hardens, it forms a solid mass. Some of these materials are naturally present in mineral soils (such as clay and lime) and may require soil conditioning to achieve the “right” profile. This means that special soils and reagents may need to be added, and other soils and reagents may need to be screened out. The earthmoving industry has a relatively high carbon footprint, increased costs, and involves industrial processes. However, engineers and authorities often prefer chemical impurities like cement because they increase technical safety factors.

[0049] It is worth noting that building module 1 can be infinitely long, even longer than the walls. If the walls have rounded corners or some kind of dome, the entire structure could be a single "spiral".

[0050] In one embodiment, by adding an additional fabric sheet 2, the building module 1 can extend beyond the cut length of the first fabric sheet 2. Near the end of the first fabric sheet, a second fabric sheet begins and wraps around the first fabric sheet as if they were one piece. Both the first and second fabric sheets are wrapped together around the filler material, and at least one edge of the wrap is held by a retaining device. This embodiment facilitates the expansion of the building module so that the module is not limited by the length of the fabric sheets.

[0051] Figure 3 A diagram illustrates a manual method for manufacturing building modules. This manual method involves laying fabric sheets 2 on an existing layer, ground, floor, or foundation of building module 1. The sheets do not need to be continuous to provide a continuous product. When one sheet ends, another sheet can be overlapped to continue. A bottomless container 8 is placed on the layer. The container is filled with soil, sand, or some other filler material 3. The filler material is compacted to a structurally satisfactory degree using a compression device 9, such as a tamper, compactor, vibrator, or even by adding fluid. An example of a fluid for a compactor / compressor is water, which is required in any case if the cohesive component is cement, lime, or other water-activated media. The first sheet edge 5 is folded inward, then the second edge 5 is folded inward, and then the wrapping is secured downward with pins 7. Other retaining devices for holding the edges can be spikes, wedges, barbed wire, glue, stitching, etc. The container 8 is then pulled forward to advance the process.

[0052] The technology of this invention can be implemented using fully mechanized or semi-mechanized equipment. The equipment may include a filling device and a folding device. The filling device includes a top portion having a top opening and a bottom portion having a bottom opening. Filling material or a compound of filling material and adhesive is applied to the fabric sheet through the top opening and the bottom opening. While the filling material or the compound of filling material and adhesive (if used) is placed on the fabric sheet, the folding device folds the edges of the fabric sheet to overlap each other. The additional procedures of compressing the filling material and securing the edges of the fibrous sheets to each other to maintain the folded portions can be performed manually or using additional mechanization.

[0053] In another embodiment, the device is further provided with a compression device that compresses the filling material when it is placed on the fabric sheet by the filling device.

[0054] In one embodiment, the device further includes a retaining device adapted for sealing a package formed by the folded ends of a fabric sheet. Sealing is achieved using adhesives, staples, or sewing devices, or combinations thereof. The sewing and staples are secured to the edges of the package and penetrate both edges, while adhesive is applied between the two edges of the package.

[0055] Figure 4 An exemplary semi-mechanized device 10 for manufacturing building module 1 is shown. The device 10 has a container 8 as a filling device. The container has a top portion with a top opening and a bottom portion with a bottom opening. Filling material is filled onto a fabric sheet through the top opening and the bottom opening. The device 10 also has a folding device 11 having two walls 12a, 12b. These walls 12a, 12b allow the filling device 8 to slide between the walls 12a, 12b, leaving a narrow gap to allow the sides of the fabric sheet 2 to pass through. The walls 12a, 12b are folded up to form the folding device 11. These can slide on a preceding building module 1 or a base. The folding device 11 may also include one or more pairs of guides 13 connected to the walls 12a, 12b of the folding device 11, and enabling easy placement of the device 10 directly onto a preceding building module 1 or a base. In an alternative embodiment, instead of allowing walls 12a and 12b to slide on the previous layer, walls 12a and 12b are placed on the previous layer's building module or foundation. In this case, the user of the device must use their own skills to properly move the device to place and form the building module. In one embodiment, no guiding device 13 is provided, and the user must use their own skills to place the device 10 on the previous layer's building module 1 or base.

[0056] Figure 5A fully mechanized apparatus 10 for manufacturing building module 1 is shown. The front of apparatus 10 has protruding flanges 14a, 14b. These flanges 14a, 14b are then twisted upwards in the middle and overlap each other at the rear. The middle and rear sections of apparatus 10 have no bottom. The front of apparatus 10 is essentially horizontal. It unfolds the fabric sheet 2 and pushes the barbs 6 into the edge 5 of the fabric sheet 2 so that it can be gripped by the flanges 14a, 14b. In the middle of the flange machine (the next section), the flanges 14a, 14b are twisted upwards (here there is no bottom, only the stretched fabric 2). This open U-shaped form behaves like a container used in the aforementioned filling device, enabling convenient and uniform filling of the filler material 3. The filler material 3 is poured into a U-shape in the fabric sheet 2 and can then be immediately compacted to the sides using compression rollers 15 from above and from both flanges 14a, 14b. Flanges 14a and 14b, together with the edge 5 of the sheet, fold over each other. At this point, pin pusher roller 21 pushes barbed wire 6 through the opposite folded portions of the fabric sheet 2 (one below and one above), thereby securing the fabric wrap around the compressed filler in the appropriate position, directly on the previous layer or base.

[0057] To compress the filler material, a compression roller 15 is provided, which compresses the filler material 3 from above when it is placed on the fabric sheet 2. In an alternative embodiment, one or more vibratory compactors can be provided to compress the filler material by means of vibration. The compression roller 15 should be heavy and may have additional spring load.

[0058] The device 10 also includes a pinning roller 17 with one or more grooves 18 that allow the barbs of the barbed wire 6 to pass through and pierce the barbs and embed the barbs into the fabric layer, while still being protruding enough to hold the building module 1 in front of subsequent layers.

[0059] The device also includes one or more reels 19 that hold the barbed wire 6 and are functionally coupled to the pinning rollers 17, so that when the device 10 moves, the reels 19 supply the barbed wire 6 to continuously attach the barbed wire to the fabric sheet 2 via a set of pinning rollers 17.

[0060] The device also includes a sheet holder 20 that holds the fabric sheet 2 and is functionally coupled to the staple roller 17 such that when the device 10 moves, the sheet holder 20 passes over the fabric sheet 2 to reach the staple roller 17.

[0061] Filling can be performed using the attached unit or a separate unit. Filling can be performed manually by one person using a shovel, bucket, or other manual equipment. However, for full automation, a conveyor running from below the hopper would be a good solution. Alternatively, the filler material can fall directly from the hopper.

[0062] The device 10 can be moved by an external propulsion mechanism. The coupling 16 to which the external propulsion mechanism is connected is provided on the device 10.

[0063] According to another embodiment of the invention, a building module (1) is provided, which consists of a fabric sheet (2) wrapped in a spiral configuration around a filling material (3) and held in place by a retaining device (4). Folded portions are formed around the filling material (3) around each spiral turn. When held in place by the retaining device (4), the edges (5) of the wrapped folded portions substantially overlap along each consecutive spiral turn.

[0064] Therefore, a building module (1) is provided, wherein the folded portion extends obliquely relative to the axis of the building module (1), the overlapping edge (5) extends obliquely relative to the axis of the building module (1), and the retaining device (4) extends obliquely relative to the axis of the fabric sheet (2) and the overlapping edge (5).

[0065] It is worth noting that if the wrapping technique used in this invention is completed with a coating, it will be more robust, because plastics and natural fibers can deteriorate in the face of ultraviolet radiation (from sunlight), fire, or physical damage. Paint can help resist ultraviolet radiation, and some coatings can also resist fire, but paint is the most effective. Temporary walls do not require paint, except in cases where further fire protection is needed.

[0066] Modules can be used to form various types of structures, such as architectural configurations, landscaping, emergency structures, and many other types. Some examples of architectural configurations are walls, floor panels, domes, vaults, arches, and doorways. Examples of landscaping uses include retaining walls, temporary retaining walls and terraced slopes, plantations, fences / farm walls, dikes, dams, water barriers, seawalls, irrigation canals, windbreaks, erosion control, soil stabilization structures, gabion replacement structures, and planted pathways (where the composition is pre-mixed into organic soil, thus making the structure "aerated" or organic). Some examples of emergency structures are firebreaks and flood dikes. Other types of structures can include water tanks, silos, septic systems, structures on the lunar surface and other solid planets, and inexpensive materials (for counterweights, etc.).

Claims

1. A building module (1), comprising: Fabric sheet (2); filling material (3); and retaining device (4); wherein the fabric sheet (2) is wrapped around the filling material (3) to form a folded portion covering the filling material (3), the fabric sheet (2) having an edge (5) folded upward and covering the filling material (3), one edge of the fabric overlapping another edge, compacting the filling material (3) inside the package, wherein the overlapping edges (5) of the folded portion of the package are held in place by the retaining device (4); the retaining device (4) is made of one or more of the following: pins, barbed wire, U-shaped nails, stakes, spikes, wedges, or stitching attached to the package; adhesive applied between adjacent overlapping edges (5) of the folded portion of the package; and an additional building module placed on top of the building module; The building module (1) is formed by securing one or more of the following: pins, barbed wire, U-shaped nails, stakes, spikes, wedges, or stitching to the wrap and penetrating both edges (5); and by placing the filling material (3) on top of the fabric sheet (2) and compacting the filling material (3) with a compression device while placing the filling material (3) on the fabric sheet (2), then wrapping the fabric sheet (2) around the compacted filling material (3) and applying the retaining device (4) to the edges (5) of the formed fold.

2. The building module (1) according to claim 1, characterized in that, The fabric sheet (2) is made of synthetic materials, natural fiber materials or a combination thereof.

3. The building module (1) according to any one of claims 1 or 2, characterized in that, The filling material (3) is selected from sand, silt, clay, gravel, other types of soil materials, organic materials, recycled waste or combinations thereof.

4. The building module (1) according to claim 3, characterized in that, The filler material also includes an adhesive made of lime, clay, cement, protein, gypsum, fiber, or glue, or a combination thereof.

5. The building module (1) according to claim 4, characterized in that, The building module (1) includes one or more fabric sheets (2), wherein the end of the second fabric sheet (2) is wrapped around one end of the first fabric sheet (2), and wherein both the first fabric sheet (2) and the second fabric sheet (2) are wrapped around the filling material (3) and one or more of the edges (5) of the wrapping are held by the retaining device (4).

6. The building module (1) according to claim 1, characterized in that, The fabric sheet (2) is wrapped around the filling material (3) in a spiral configuration, thereby continuously forming the folded portions covering the filling material (3) around each turn of the spiral, and the edges (5) overlap each other between the consecutive turns of the spiral. The folded portions extend obliquely relative to the axis of the building module (1), the overlapping edges (5) extend obliquely relative to the axis of the building module (1), and the retaining device (4) extends obliquely relative to the axis of the fabric sheet (2) and the overlapping edges (5).

7. A method for manufacturing a building module (1) according to claim 1, the method comprising the following steps: Lay out a fabric sheet (2); place a filling material (3) on top of the laid fabric sheet (2); while placing the filling material (3) on the fabric sheet (2), compact the filling material (3) from top using a compression device; wrap the fabric sheet (2) upwards and cover the compacted filling material (3) by folding one side of the fabric sheet (2) along the length of the fabric sheet (2) to the other side, such that one edge (5) of the fabric sheet (2) covers the other edge (5); and provide a retaining device (4) to securely hold the wrapping of the fabric sheet (2).

8. An apparatus (10) for manufacturing a building module (1) according to any one of claims 1 to 5, the apparatus (10) comprising: A filling device (8) comprising a top portion having a top opening and a bottom portion having a bottom opening, the filling device (8) being arranged to receive filling material (3) through the top opening and to distribute the received filling material (3) onto a fabric sheet (2) arranged below the device (10) through the bottom opening. A folding device (11) adapted to fold the edges (5) of the fabric sheet (2) to cover each other when the filling material (3) is placed on the fabric sheet (2); and a compression device (9) disposed between the filling device (8) and the folding device (11) and adapted to compress the filling material (3) from above when the filling material (3) is placed on the fabric sheet (2) by the filling device (8).

9. The device (10) according to claim 8, characterized in that: The folding device (11) includes two walls (12a, 12b), the filling device (8) is slidable between the two walls and leaves a gap; and the gap between the filling device and the walls (12a, 12b) is adapted to receive the side of the fabric sheet (2) so that the side of the fabric sheet passes through it.

10. The device (10) according to claim 9, characterized in that, The walls (12a, 12b) of the folding device (11) are also adapted to slide on the base or other building modules, such that the building modules (1) made by the device (10) are respectively manufactured on the top of the base or the other building modules.

11. The device (10) according to claim 10, characterized in that, The device further includes one or more pairs of guide devices (13), which are connected to the walls (12a, 12b) of the folding device (11), and the guide devices (13) enable the device (10) to be positioned directly on the base or on top of another building module.

12. The device (10) according to any one of claims 8 to 11, characterized in that: The folding device (11) includes two flanges (14a, 14b) adapted to the edge (5) that receives the fabric sheet (2), the edge being attached thereto; Unfold the front portion of each of the flanges (14a, 14b) such that each of the edges (5) attached thereto is laid as it approaches the front portion; bend the middle portion of each of the flanges (14a, 14b) upward such that the fabric sheet (2) is shaped to receive and contain the filling material and is able to compact the filling material as it approaches the middle portion; and shape the rear portion of each flange (14a, 14b) to become parallel to the other flange such that each of the edges (5) attached thereto is guided to form the folded portion, wherein the edges (5) overlap each other as they approach the rear portion.

13. The device (10) according to claim 8, characterized in that, The compression device (9) includes one or more compression rollers (15) that compress the filling material (3) from above when the filling device (8) places the filling material (3) on the fabric sheet (2).

14. The device (10) according to claim 8, characterized in that, The compression device (9) includes one or more vibratory compactors that compress the filling material (3) from above when the filling device (8) places the filling material (3) on the fabric sheet (2).

15. The device (10) according to claim 8, characterized in that, The device also includes a stapling roller (17) with one or more grooves (18), whereby the barbs of the barbs (6) pass through the one or more grooves (18) to pierce the fabric layer and embed the barbs into the fabric layer, and a portion of the barbs protrudes outside the fabric layer to hold the building modules (1) of subsequent layers.

16. The device (10) according to claim 15, characterized in that, When the barbs of the barbed wire (6) are embedded in the side of the fabric sheet (2), the side of the fabric sheet (2) is guided by flanges (14a, 14b) to fold the fabric sheet (2) around and cover the filling material (3) and cover each other, and when the device (10) moves, the barbs of the barbed wire (6) are embedded in the folded portion formed.

17. The device (10) according to any one of claims 15 or 16, characterized in that, The device further includes a spool (19) that holds the barbed wire (6) and is functionally coupled to the pinning rollers (17), whereby, when the device (10) moves, the spool (19) supplies the barbed wire (6) to continuously attach the barbed wire to the fabric sheet (2) via a set of the pinning rollers (17).

18. The device (10) according to claim 15, characterized in that, The device further includes a sheet holder (20) that holds the fabric sheet (2) and is functionally coupled to the pinning roller (17), such that when the device (10) moves, the sheet holder (20) passes over the fabric sheet (2) to reach the pinning roller (17).

Images