Air Forming Building System

Abstract

The composite structure can be built using an air forming process that includes filling an expanded support form with a fluid structural material and allowing the fluid structural material to harden within the support form. Additional steps can include inflating the support form with a first fluid, forming a fluid outlet in the support form, and removing the support form after the fluid structural material has hardened. The first fluid can be air, the support form can be fiberglass resin, and / or the fluid structural material can be a concrete composite. The fluid can exit through the fluid outlet during the filling step. The completed structure can include multiple structural components formed from a homogenous concrete composite and having a curved non-planar shape. The concrete composite can include aluminum alloy fibers.

Description

[Technical field]

[0001] This application claims the benefit of U.S. Patent Application No. 17 / 173,206, filed February 10, 2021, the contents of which are incorporated by reference in their entirety.

[0002] Technical Field FIELD OF THE DISCLOSURE This disclosure relates generally to the formation of structures, and more particularly to the formation of buildings, statues, and other structures made from hardened fluid structural materials such as concrete. [Background technology]

[0003] background Concrete has long been a common ingredient in the formation of structures, buildings, bridges, highways, and the like because it is a strong material, especially in terms of compressive strength and the support it provides to structures. Common uses of concrete structural elements include columns, beams, joists, panels, and slabs, as well as other flat, straight, and / or rectilinear structures. Concrete can also be used to form curved and more complex structures, such as manholes, drains, pipes, and other curved segments.

[0004] Unfortunately, it is usually difficult and / or expensive to create unusually shaped structures using traditional concrete formwork techniques. Concrete structures with complex or curved surfaces can require additional material, labor, or time to form. Such structures typically involve the use of rebar or other internal reinforcement used in more rigid building materials, and require numerous structural elements, such as those described above, to be formed or assembled in stages and joined together by a variety of different means and techniques.

[0005] While traditional methods of forming structures have worked well in the past, advances are always useful. In particular, what is needed are complex structures and methods of forming complex structures that overcome traditional limitations in the labor-intensive and time-consuming nature of structural formation, especially concrete structures. Summary of the Invention [Problem to be solved by the invention]

[0006] overview An advantage of the present disclosure is to provide improved structures and methods of forming structures that overcome traditional limitations in the formation of structures. The disclosed features, apparatus, systems, and methods provide improved structure forming solutions, including the use of improved composite materials and improved methods of forming structures, particularly with respect to concrete. These advantages are achieved, at least in part, through the use of aluminum alloy fiber reinforced concrete and / or the use of expandable support forms during the formation of structures, such as concrete composite structures. [Means for solving the problem]

[0007] In various embodiments of the present disclosure, the structure forming system can include an inner support mold, an outer support mold, and one or more separator system components. The inner support mold can have a first thickness and a first injector, and the inner support mold can be configured to be filled with a fluid support material or structural material via the first injector. The outer support mold can be disposed around the inner support mold and can have a second thickness and a second injector. The outer support mold can be configured to be filled with a fluid structural material via the second injector, such that the fluid structural material fills a volume between the outer support mold and the inner support mold. The separator system component can be connected to the inner support mold and the outer support mold at one or more points along the inner support mold and the outer support mold to space the inner support mold a set distance from the outer support mold. The structure forming system can be configured to form a hollow structure from the fluid structural material when the fluid structural material hardens within the structure forming system.

[0008] In various detailed embodiments, the structural forming system may include concrete. Each separator system component may include a rigid separator pipe and a contact plate on each of the inner and outer support forms. In one configuration, the hollow structure may be a chamber, and the hardened fluid structural material may form one or more walls of the chamber. Additionally, the outer support form may include one or more pressure valves configured to release pressure when the outer support form is filled with the fluid structural material.

[0009] In various further embodiments of the present disclosure, the concrete structure may include a first structural component formed from a homogenous material and a second structural component formed from a homogenous material. The homogenous material may include concrete and embedded fibers having a thickness of less than about 2 mm and a length of less than about 30 mm. The first structural component may include at least a first portion having a first curved non-planar shape and the second structural component may include at least a second portion having a second curved non-planar shape that is substantially different from the first curved non-planar shape. In some configurations, the first structural component and the second structural component may be integrally formed. In various detailed embodiments, the embedded fibers may include fibers having an aluminum alloy composition. Additionally, the concrete structure may be formed using one or more expandable support forms.

[0010] In further embodiments of the present disclosure, various methods of forming a structure are provided. The associated processing steps may include forming one or more fluid outlets in a first support mold, filling the first support mold with a fluid structural material, where fluid can exit through the one or more fluid outlets during filling, and hardening the fluid structural material in the filled first support mold, where the hardened structural material forms at least a portion of the structure.

[0011] In various detailed embodiments, further processing steps may include wetting the first support form prior to filling and removing the expanded first support form after the fluid structural material has hardened. In one expanded configuration, the first support form may be expanded with a first fluid prior to filling, where the first fluid exits one or more fluid outlets during filling. The first fluid may include air and / or the first support form may include fiberglass resin balloons. The fluid structural material may include a fluid concrete composite material, and the hardened structural material may include a hardened concrete composite material. The concrete composite material may include fibers intermixed therein, and the fibers may have an aluminum alloy component. The aluminum alloy fibers may have a thickness of less than about 2 mm and a length of less than about 30 mm, but may be of other sizes.

[0012] In various detailed embodiments, further processing steps may include expanding the second support mold with a first fluid, forming one or more fluid outlets in the second support mold, filling the expanded second support mold with a fluid structural material, the first fluid exiting through the one or more fluid outlets during filling, and hardening the fluid structural material within the expanded second support mold, the hardened structural material forming at least a portion of the structure. In some configurations, some support molds are filled only with air or another first fluid, and not with the fluid structural material. Processing steps may further include designing the first support mold and fabricating the first support mold. In some embodiments, the formed structure may include at least a first structural component having a first curved non-planar shape and a second structural component having a second curved non-planar shape substantially different from the first curved non-planar shape. Additional processing steps can include connecting the first support form to the foundation of an existing building. The completed structure can include a building, statue, or other structural component.

[0013] Other devices, methods, features, and advantages of the present disclosure will be, or will become, apparent to one with skill in the art upon examination of the following figures and detailed description, and it is intended that such additional devices, methods, features, and advantages be included within this specification, be within the scope of the disclosure, and be protected by the accompanying claims. [Brief description of the drawings]

[0014] BRIEF DESCRIPTION OF THE DRAWINGS The included drawings are for illustrative purposes only and are intended to provide examples of possible constructions and configurations of the disclosed apparatus, systems, and methods for air-formed structures, and are in no way intended to limit the changes in form and detail that may be made to the present disclosure by those skilled in the art without departing from the spirit and scope of the present disclosure.

[0015] FIG. 1 illustrates a side perspective view of an example base and support arm structure made by an air forming process according to one embodiment of the present disclosure.

[0016] FIG. 2 illustrates a flow chart of an exemplary method for creating a structure through an air-forming process in accordance with an embodiment of the present disclosure.

[0017] FIG. 3 illustrates a side cross-sectional view of an example of an inflated mold during the creation of a structure by an air forming process according to one embodiment of the present disclosure.

[0018] FIG. 4 illustrates a side perspective view of an example of an arched continuous dome structure made by an air forming process according to one embodiment of the present disclosure.

[0019] FIG. 5 illustrates a side perspective view of an example of a turtle shell structure made by an air forming process according to one embodiment of the present disclosure.

[0020] FIG. 6 illustrates a side perspective view of an example post and lintel structure made by an air forming process according to one embodiment of the present disclosure.

[0021] FIG. 7 illustrates a side perspective view of an example of an outer and inner beehive structure created by an air forming process according to one embodiment of the present disclosure.

[0022] FIG. 8 illustrates a side perspective view of an example of a hollow structure made by an air forming process according to one embodiment of the present disclosure.

[0023] FIG. 9A illustrates a side cross-sectional view of an example double support mold inflated during fabrication of the example hollow room structure of FIG. 8, according to one embodiment of the present disclosure.

[0024] FIG. 9B illustrates a side cross-sectional view of an example separator system component for use with the inflated dual support of FIG. 9A, according to one embodiment of the present disclosure.

[0025] FIG. 10A illustrates a side perspective view of an example of an image structure created by an air-forming process according to one embodiment of the present disclosure.

[0026] FIG. 10B illustrates an example of the image of FIG. 10A in a side cross-sectional view, according to one embodiment of the present disclosure.

[0027] FIG. 11A illustrates a side cross-sectional view of an example of a reinforcing bar supported foundation connection according to one embodiment of the present disclosure.

[0028] FIG. 11B illustrates a front cross-sectional view of an example of a connection to a support type foundation socket according to one embodiment of the present disclosure.

[0029] FIG. 12 illustrates a flow chart of an example of another method for forming a structure using an alternative formation process, according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0030] Detailed Description Exemplary uses of the devices, systems, and methods according to the present disclosure are described in this section. These examples are provided only to add background information and aid in the understanding of the present disclosure. Thus, it will be apparent to one of ordinary skill in the art that the present disclosure may be practiced without some or all of those specific details set forth herein. In some examples, well-known processing steps have not been described in detail to avoid unnecessarily obscuring the present disclosure. The examples described below should not be taken as limiting, and other applications may be realized. In the following detailed description, reference is made to the accompanying drawings, which form a part of the specification, and which are shown therein by way of example specific embodiments of the present disclosure. These embodiments are described in sufficient detail to enable one of ordinary skill in the art to practice the present disclosure, but it will be understood that these examples are not limiting, and that other embodiments may be used and changes may be made without departing from the spirit and scope of the present disclosure.

[0031] The present disclosure, in various embodiments, relates to features, devices, systems, and methods used in air-formed structures, which may include buildings, statues, and other structural objects. The disclosed embodiments may include various methods and techniques for the formation of three-dimensional structural elements using an "air-forming process," as well as the three-dimensional structural elements themselves. In particular, the disclosed embodiments may utilize an inflated balloon or support mold of any size or shape that serves as a form that is filled with the structural material, minimizing human intervention and labor to impart the final shape to the structural element. The air-formed structure support device or form may be a balloon, mold, or other similar device, but all such forms are collectively referred to as a "support mold" for purposes of this disclosure.

[0032] The disclosed embodiments provide a more economical option for the construction of complex, unitary structures and structural elements, especially those involving concrete and other similar materials, by shifting a portion of the labor costs to the manufacturing of forms. Since the fabrication of a completely on-site structure requires approximately 72 hours or less, time savings is another attractive feature of the disclosed construction process that can reduce costs and labor.

[0033] In various embodiments, the support form may be initially filled with air, although other suitable fluids may be used. Thus, although the term "air forming" and various derivatives thereof are used throughout this disclosure, it will be understood as a consequence that any suitable fluid other than air may be used in the process of filling and forming the support form. Then, in various embodiments, the inflated balloon or support form may be filled with a structural material fluid, during which the air or other inflating fluid is also evacuated. Such a structural material may be a concrete-like hybrid material disclosed herein, such as an aluminum alloy fiber-reinforced hybrid material, although it will be understood that various other structural materials may alternatively be used, such as plastic materials, other melting materials, or other materials that solidify, such as water that solidifies into ice, among other available materials. Thus, the structural material fluid filled into the form may be allowed to harden, after which the form may be removed to provide the final formed structure or element of the structure.

[0034] In various alternative embodiments, which are merely illustrative and in no way limiting, the step of filling the support form with air or an initial fluid can be omitted in favor of directly filling the support form with the structural material itself. Additional steps may include designing the support form and fabricating the support form. Multiple support forms can also be used, with the appropriate steps being repeated for each different support form. The structural elements formed from each support form can then be combined to form an entire structure, such as a building, statue, or freestanding design, among other possible structures.

[0035] 1 illustrates an example of a base and support arm structure made by an air forming process in a side perspective view. The base and support arm structure 100 may be a single structure made by an air forming process using a balloon or a support mold. The structure 100 may be, for example, an underlying support structure that may be used to form components of another structure at or on top of it. Thus, the structure 100 may include a base 110 and a number of support arms 120 extending therefrom. The base 110 may be formed on the ground or on a remote foundation, and one or more support arms 120 may be used to support one or more other components, some or all of which may also be formed by the air forming process.

[0036] A variety of materials may be used to form the structure 100, and in particular, it is contemplated that fluid (e.g., wet) building materials may be used along with such building materials that can be cured or hardened to form a finished structure. In particular, concrete and concrete composite materials are contemplated for the disclosed air-forming process. While traditional building methods and techniques using concrete may be limited, the disclosed air-forming process may be used to greatly expand the variety of complex shapes that can be formed using concrete and concrete composite materials. The structure 100 is an example of a unitary concrete or concrete composite structure that cannot be formed by traditional methods, but can be formed by the air-forming process as disclosed herein.

[0037] 2 shows a flow chart of an example method 200 for making a structure using an air forming process. It will be readily understood that the method 200 is a high level overview and various steps and details are not shown at this point for the sake of brevity. The structure can be a building or part of a building, and can be a statue, a freestanding monument, or various other types of structures. After a start step 202, a first processing step 204 can include inflating a support form. The support form can be, for example, a fiberglass resin material arranged into a customized shape, and air can be used to inflate the support form, although other support form materials and fluid inflation media can be used.

[0038] In a subsequent processing step 206, the expanded support form can be filled with a fluid structural material. Such a fluid structural material can be, for example, a fluid concrete composite. In particular, a concrete composite with aluminum alloy fibers embedded therein can be used. In one configuration, air or other fluids used to expand the support form can exit through one or more fluid outlets while the support form is being filled with the fluid structural material. Suitable aluminum alloy fibers can be produced, for example, by cutting a portion of an aluminum beverage can into thin strips, as described below.

[0039] In the next processing step 208, the fluid structural material may be allowed to harden, which occurs while the fluid structural material fills the support form and assumes the shape of the support form. If a concrete or concrete composite is used, for example, the fluid structural material may harden for about 48 to 72 hours, although other time periods are contemplated.

[0040] In a subsequent processing step 210, the support form can then be removed from the hardened structural material, so that only the final structure remains. In some configurations, the support form may be a disposable support form and may be destroyed during the removal process. In other configurations, the support form may be a reusable support form and the support form may be carefully removed to preserve it for future use. In some configurations, the support form may form part of the completed structure such that it does not need to be removed (i.e., there is no step 210). The method then ends in end step 212.

[0041] Continuing with FIG. 3, an example of a support mold inflated by an air forming process during the creation of a structure is shown in side cross-section. The support mold 300 may be, for example, a balloon inflated with air or other suitable fluid and may be used to form the base and support arm structure shown in FIG. 1. Thus, the support mold 300 may include a base region 310 and a number of support arm regions 320. When inflated, the support mold 300 may include a thin layer 302 filled with air or other fluid and an internal hollow region 304. This may be achieved by one or more fill ports 330, which may also be used to fill the support mold 300 with a fluid construction material, such as a composite concrete material. One or more fluid outlets 340 allow air or other fluids to escape during the building process.

[0042] In one configuration, the surface texture of the finished structure can be achieved or altered by adjusting the surface texture of the mold used to form the finished structure. For example, the support mold 300 can be provided with a customized texture on its inner surface that hardens after the fluid construction material fills the mold. If the inner surface of the support mold is very smooth, then the outer surface of the finished structure formed from the composite concrete or other fluid construction material will also achieve a smooth finish. Conversely, if the inner surface of the support mold is rough, then the surface texture of the finished structure will also be rough.

[0043] In the following Figures 4-10B, various possible use cases are provided for the wide variety of structures that can be formed using the disclosed air forming process. It will be understood that the various structures that can be made by means of air forming can be of virtually any shape or size, and the various use cases disclosed herein are only a small sample of the myriad of structures that can be formed. The structures can be based on various materials and can be formed in a variety of environments, including, but not limited to, various indoor, outdoor, underwater, vacuum space, outer space, and other environments. The structural materials can include anything that hardens over time, such as concrete, resins, molten metals or alloys, water or water-based fluids, among other possible materials. Various liquids that can harden by chemical reaction can also be used.

[0044] 4 shows an example of an arched dome structure made by an air forming process in a side perspective view. The arched dome structure 400 can be a single structure made by an air forming process using a single balloon or a single support mold. The arched dome structure 400 can be a dome made of a series of multiple arches 410, for example.

[0045] FIG. 5 shows an example of a turtle shell structure made by an air forming process in a side perspective view. The turtle shell structure 500 may be a unitary structure made by an air forming process using a single balloon or a single support mold. The turtle shell structure 500 may be, for example, a free-standing or "skeletal" structure that can be formed on or used to attach to other structural components. Thus, the turtle shell structure 500 may include a relatively low, surrounding base 510 and multiple arms 520 extending from the base 510 that are interconnected to form a skeletal turtle shell shape.

[0046] FIG. 6 shows an example of a post-and-lintel structure made by an air-forming process in a side perspective view. The post-and-lintel structure 600 may be a combined structure made by an air-forming process using multiple balloons or multiple support forms. The post-and-lintel structure 600 may be a structure of a single post and connected lintel or platform, for example, used to support various other components or objects thereon. Thus, the post-and-lintel structure 600 may include a base 610, multiple lintels 620 extending upwardly from the base 610, and a platform 630 contained within the multiple lintels 620. The base 610 may be formed on the ground or on a separate foundation and may be formed from one balloon or one support form. One or two additional balloons or support forms may be used to form the multiple lintels 620 and platforms 630. In some configurations, rebar supports, such as in the form of rebar beam frames, may be inserted to provide additional support to the overall structure.

[0047] FIG. 7 shows an example of an outer and inner beehive structure made by an air forming process in a side perspective view. The beehive structure 700 can be a single structure made by an air forming process formed with one balloon or one support mold, or with two separate balloons or support molds. The beehive structure 700 can be, for example, an outer overall structure that can be used to house other components and / or objects contained therein. Thus, the beehive structure 700 can include an outer honeycomb or beehive structure 710 and an inner structure 720 contained therein. In some configurations, steel ropes 730 or other suspension components can be used to suspend the beehive structure 700.

[0048] FIG. 8 illustrates a side perspective view of an example of a hollow structure made by an air forming process. The hollow structure 800 may be made of concrete or concrete composites, for example, by one or more of the various air forming processes disclosed herein. In one configuration, the hollow structure 800 may be a room formed in an elevation with a staircase below that leads to a room inside the hollow structure. The hollow structure 800 may be of any size or shape, such as a cube, sphere, ball, pear, apple, or the like. In another configuration, the hollow structure 800 may be enclosed within a room within a larger building or structure, such as a cube-shaped glass structure.

[0049] In various embodiments, the hollow structure 800 may be a large indoor room such as a conference room, a reception area, or even a movie theater. For example, the hollow structure 800 may be a movie theater equipped with one or more projection devices that project photos and / or videos onto a part or the whole of the interior walls of the hollow structure 800. Fog, laser beams, and other effects may be used on the interior walls of the hollow structure 800 for a more dynamic indoor presentation. Again, the texture of the interior walls can be set to the desired smoothness and / or type of texture of the mold used for the interior walls during the formation of the hollow structure 800. For example, a nice smooth texture of the interior walls can be set by having a very smooth feel mold on the interior wall surface, while a rough or customized tactile texture can be set by using a mold with an inverse shape of the desired texture on the interior walls of the hollow structure 800.

[0050] FIG. 9A shows a side cross-sectional view of an example of an inflated double support mold used during the fabrication of the example hollow structure of FIG. 8. As can be readily seen, the hollow structure 800 of FIG. 8 can be a relatively complicated structure to form. Therefore, multiple support molds can be used to form the structure. For example, an inner support mold 952 can be included inside an outer support mold 954 to form a structure having a hollow interior, such as the hollow room structure 900.

[0051] The first injector 960 can be used to fill the inner support form 952 with air, another fluid support, or other structural material, and the second injector 962 can be used to fill the outer support form 954 with air or other fluid. The other structural material can be a lightweight material, such as a foam material, designed to maintain the shape of the inner support form during construction. As can be easily seen, the fill volume required for the second injector 962 can simply be the volume between the outer support form 954 and the inner support form 952. And the third injector 964 can be used to fill a volume equal to the fill volume between the two supports with a fluid structural material, such as fluid concrete or a concrete composite.

[0052] One or more pressure valves 970 may be formed within and positioned along the outer support mold 954 to check and release pressure as needed during expansion of the outer support mold 954 and / or during filling of the outer support mold 954 with the fluid structural material. Similar pressure valves may be used for the inner support mold 952 as needed. Additionally, one or more separator system components 970 may be used to hold the inner support mold 952 and the outer support mold 954 together a set distance apart during the building process.

[0053] FIG. 9B shows an example of a separator system component in a side cross-sectional view for use with the expanded double support mold of FIG. 9A. The separator system component 980 can be used to maintain the inner support mold 952 and the outer support mold 954 at a set distance during the air forming expansion and filling process. In various configurations, multiple identical or similar separator system components 980 can be spaced along the surfaces of the inner and outer support molds to facilitate substantially uniform spacing between the supports and thus a substantially uniform thickness in the components of the finished hollow room structure or other structure formed by similar double support mold processing. Each separator system component 980 can include a rigid separator pipe 982 with a length corresponding to the desired thickness of the wall of the finished hollow structure. Contact plates 984 may be disposed along the outer surfaces of both the inner support mold 952 and the outer support mold 954, and the separator pipe 982 may pass through these contact plates 984, and tightening nuts 986 may be attached to the outer surfaces of both supports. Alternative structures may be used to facilitate uniform spacing between supports in configurations such as dual supports.

[0054] While many use cases may involve the formation of architectural structures or components of architectural structures, the disclosed air forming process may also be used to create other types of structures. For example, air forming may be used to create statues or other free-standing decorative structures. Statues made from concrete or concrete composites using the disclosed process can be made much faster and significantly cheaper than the typical use of steel, bronze, or other metals. Structures such as statues may use concrete or concrete composites, or alternative construction materials may be used as described above.

[0055] As shown in Figures 10A and 10B, a free-standing dinosaur statue 1000 may be formed using the disclosed air forming process. A wide variety of statue structure shapes and sizes can be formed by controlling the center of gravity of the statue and designing one or more support molds. For example, if the statue structure design is mostly toward one foot or base 1002 of the statue, the weight of the solid portion 1004 of the statue 1000 on one side of the base 1002 can compensate for the weight of the hollow portion 1006 of the statue 1000 that extends away from the base 1002 on the other side of the solid portion.

[0056] In various embodiments, statues or decorative structures formed by the disclosed air forming process may include a process of adding pigments to the fluid construction material during formation. For example, during the formation of the dinosaur statue 1000, a concrete structure may have a brown color material added to the wet concrete. Additional paint ingredients or decorative materials may be added to the hardened and completed structure as needed. As mentioned above, the finished texture of the dinosaur statue 1000 may also be set by adjusting the texture of the mold used to form the statue. For example, a textured mold may provide a textured surface of the statue 1000 to mimic the skin of the dinosaur. Different surface textures may also be achieved by varying the texture at different points on the mold. For example, a textured texture may be used for the skin of the rough dinosaur, while a smooth texture may be used for a smooth finished surface such as the surprised scientist, as needed.

[0057] As will be readily apparent, the various structures and components of structures in Figures 4-10B are only a few of the many different concrete and other structures that may be formed using the various air forming methods disclosed herein. In various embodiments, one or more support forms may be defined by any shape, size, and complexity. The material for each support form may be fiberglass resin or any other suitable material, such as, for example, a resin-like or fiberglass and epoxy fabric. The fiberglass and epoxy fabric may be wetted and allowed to cure for 24 hours. In other configurations, the form created using the support form may be disposable, to be demolished after the concrete has cured. That is, the support form itself does not constitute any part of the final formed structure.

[0058] In some embodiments, each support mold may be a disposable support mold that is destroyed or disposed of after removal. In alternative embodiments, one or more of the support molds may be reusable. For example, some support molds may be removable so that they can be reused several times to create the same structure. Some support molds may even be removable and reusable an indefinite number of times. To facilitate reuse of such reusable support molds, one or more flaps, seals, zippers, or other suitable features may allow removal of the support mold after molding without destroying the reusable support mold.

[0059] In various embodiments, the fluid building material need not be limited to concrete. In fact, any other material that can be poured into a mold as a homogenous fluid and subsequently hardens to produce a solid structure can be used. For example, alternative building materials for space applications can include the hardening resins, epoxies, or other suitable building materials described above. In other configurations, the support mold can be heated to ensure that the solidifying building material remains in a liquid state by simply turning off the heater.

[0060] In various embodiments, one or more of the supported forms may be sectioned, such that one supported form may have multiple sections that may be separately inflated connected to it, allowing for greater control over the overall form and finished structure, especially for larger and / or more complex shapes and applications.

[0061] In some embodiments, post-tensioning may be used. For example, a sleeve or pipe may be placed inside the former such that the ends are secured and accessible inside the former once the former is peeled or otherwise removed. The sleeve may include fastener elements or the fastener elements may be attached to the outside. The sleeve may be a separate item or may be an integral part of the former, made seamlessly from the same material to create a "pipe" inside the final hardened concrete. Alternatively, a "hard balloon" epoxy resin option may include drilling holes at both ends, threading the pipe through the drilled holes, and closing the ends before pouring in the fluid concrete or any other suitable fluid construction material.

[0062] In various embodiments, the support mold may be designed to be cast with multiple edges of the mold that are beveled or chamfered so that the hardened, finished structure has beveled or chamfered edges. Beveled edges aid in spalling and demolding because they ensure there are no straight or sharp angles that can lead to chipped edges. Another advantage of incorporating one or more beveled edges and / or chamfered edges is that these features can hide small, unavoidable imperfections in the pour that may otherwise be more noticeable after assembly.

[0063] In the disclosed embodiment, the natural shape of the inflatable support mold allows for the creation of rounded edges, a desirable design decision that may otherwise be unnecessary due to the relative complexity or difficulty of fabrication. Alternative design configurations can take into account the materials used to make the different elements to limit the minimum shape and sharpness of the finished edges. If the design requires sharp edges, there are always aesthetic finishing elements that can be used and added to the structure when plastering, tiling, painting, etc.

[0064] In various embodiments, the completed structure or structural components include composite concrete using any form of reinforcing steel or other separate materials. Indeed, it is specifically believed that the disclosed structures are formed from one homogenously mixed composite material without the addition of other materials or separate reinforcing components. In some configurations, the concrete portion of the composite concrete material may contain up to twice as much cement or fine particles per unit volume as regular precast concrete. Generally, small aggregates may provide a "micro-concrete" material. For example, some micro-concrete materials may have a maximum size of 2 mm. The type of concrete used may include self-compacting concrete, lightweight concrete, and / or ultra-high performance concrete as defined by the American Concrete Institute.

[0065] Since most concrete forms have stress and tension related shrinkage, homogeneous composite concrete mixtures may contain large amounts of fibers, possibly mixtures of different types of fibers (e.g., metal, polymer, etc.), to counteract such shrinkage effects. In addition to the typical structural fibers, smaller "anti-cracking" fibers can be added to the composite concrete material to reduce or eliminate small cracks that can be caused by shrinkage.

[0066] There are many different types of fibers that can be used in concrete, ranging from the standard and widespread to the highly experimental; fabric reinforcement can be considered as a "structured" fiber reinforcement, as well as fibers and fabrics that are applied on the surface of the element rather than dispersed in the concrete mass. Looking at fibers, there are two broad categories: structural and non-structural. Structural fibers are at least as large as the relatively large aggregate particles, so that they can intertwine with the aggregate particles and transfer their structural properties to the concrete. The various types of fibers that can be included in a composite concrete mixture can include steel fibers or "Dramix" fibers, structural polypropylene fibers, and non-structural polypropylene fibers, among others.

[0067] In various embodiments, aluminum alloy fibers may be mixed into the concrete material. Such aluminum alloy fibers may be formed, for example, by cutting aluminum beverage cans. In one configuration, this may involve removing the top and bottom of the aluminum beverage can and cutting the sidewalls of the can into string shapes to form the fibers. In one configuration, the strings or fibers may have a length of less than approximately 30 mm and a thickness of less than 2 mm. The width of the strings or fibers may vary as appropriate for a given application or structure.

[0068] In addition to including fibers in building materials, it is also possible for fibers to be incorporated into the fabric of a support mold. For example, one approach involves hydrating an epoxy resin and curing it to create a fiberglass and epoxy balloon or support mold that can hold its shape once expanded. Adding fibers to the support mold can strengthen the fabric material of the support mold, allowing larger and more complex structures to be realized.

[0069] 11A and 11B show examples of form-to-foundation connections in side and front cross-sectional views, respectively. The configuration 1100 of FIG. 11A shows one approach for connecting a form structure to an existing foundation. Prior to assembly and installation of one or more forms 1110, the overall structure foundation 1120 can be finished and prepared for connection to one or more elements of the structure to be cast using the form 1110. One or more rebar components 1122 can extend from the overall structure foundation 1120 that can be connected to the structure formed inside the form 1110 using connection flanges 1124. The foundation and footing can follow any appropriate standard operating procedure for precast construction.

[0070] Configuration 1150 of FIG. 11B shows another approach to connect the structure of the form with the existing foundation. As shown, it may include a vertical element, for example a precast column 1152, which can be partially introduced into the socket 1154 and fixed in situ after assembly. Alternative mechanisms such as bolted column shoes, anchor bolts and / or welded anchor plates may also be used. In one configuration, a ribbed lost formwork element 1156 may be used, which remains embedded in the concrete and ensures a good connection with the footing socket. The gap between this element and the foundation socket may be filled with a cementitious grout 1158 or other suitable material, which may be a normal procedure in precast construction. In one configuration, a metal element may be connected to the form.

[0071] FIG. 12 illustrates a flow chart of an example of an alternative method 1200 of forming a structure using an alternative forming process. The alternative method 1200 may be similar to the method 200 described above, with the notable exception that the support form does not need to be first expanded with air or any other fluid. Rather, the fluid concrete or other structural material may be directly filled into the support form without any prior fluid expansion process. It will be readily apparent that the method 1200 provides a broader alternative forming process in greater detail, and various steps and details not shown may also be included. For example, the added details may include forming multiple structural components using multiple separate support forms to complete an overall combined structure. Again, the overall structure may be a desired building, statue, or any other suitable structure.

[0072] After the start step 1202, a first processing step 1204 may include designing a support form. This may include determining what the components of the desired final structure will be, and then using software and / or other planning techniques to design a support form that will result in the components of the desired final structure.

[0073] In the next processing step 1206, a support mold may be fabricated according to the design determined in step 1204. Again, the support mold may be formed from a fiberglass resin material having an appropriate thickness and strength. Alternatively, a flexible plastic fabric may be used rather than fiberglass resin. In yet other configurations, a flexible epoxy resin and fiberglass material may be used to create the support mold.

[0074] A subsequent decision step 1208 may then be made to inquire as to whether all desired support forms have been created. If all desired support forms have not been created, then steps 1204 and 1206 may be repeated until a desired number of support forms have been created that can form all desired multiple structural components to complete the overall structure. In one configuration, step 1204 may be repeated until all support forms have been designed, and then step 1206 may be repeated until all support forms have been created using the design drawings.

[0075] In a next processing step 1210, the support mould may be directly filled with a fluid structural material, for example a wet concrete composite, which may be any of the materials mentioned above, for example with one or more fibrous materials embedded therein.

[0076] A query may then be made as to whether all of the support molds have been filled with the fluid structural material at decision step 1212. If all of the support molds have not been filled with the fluid structural material, then step 1210 may be repeated and additional structural molds may be filled until all of the desired structural molds have been filled.

[0077] In the next processing step 1214, the fluid structural material may be cured within the support mold or molds, which again may require approximately 48 to 72 hours, although other times may be required depending on the particular materials and temperatures used and the size of the overall cured structure.

[0078] In a subsequent processing step 1218, one or more support forms may be removed to leave one or more components of the completed structure, which may include removing and potentially destroying a disposable support form or carefully removing a reusable support form, as appropriate, and the method ends in end step 1220.

[0079] Although the foregoing disclosure has been described in detail by way of illustration and example for purposes of clarity and understanding, it will be recognized that the foregoing disclosure may be embodied in numerous other specific variations and embodiments without departing from the spirit or essential characteristics of the disclosure. It will be understood that certain changes and modifications may be practiced and that the disclosure should not be limited by the foregoing details, but rather should be defined by the appended claims.

Claims

1. 1. A method of forming a building structure, comprising: forming one or more fluid outlets in a first support form comprising a pliable, expandable material; Inflating the first support form with a first fluid; substantially filling the expanded first support form with the fluid structural material such that the fluid structural material assumes the complete shape of the expanded first support form, the first fluid exiting the first support form through the one or more fluid outlets during the filling; allowing the fluid structural material to harden within the filled first support mold, the hardened structural material forming at least a portion of the structure. method.

2. moreover, Wetting the first support form prior to filling; removing the first support mold after the fluid structural material is cured; The method of claim 1.

3. The method of claim 1 , wherein the first fluid comprises air.

4. The method of claim 1 , wherein the first support mold comprises a fiberglass resin balloon.

5. The method of claim 1 , wherein the fluid structural material comprises a fluid concrete composite and the hardened structural material comprises a hardened concrete composite.

6. The method of claim 5 , wherein the fluid concrete composite material includes fibers mixed therein, the fibers having an aluminum alloy component.

7. 7. The method of claim 6, wherein the aluminum alloy fibers have a thickness of less than about 2 mm and a length of less than about 30 mm.

8. moreover, expanding a second support form with the first fluid; forming one or more fluid outlets in the second support mold; filling the expanded second support form with the fluid structural material, the first fluid exiting through one or more fluid outlets during the filling; allowing the fluid structural material to harden within the expanded second support mold, the hardened structural material forming at least a portion of the structure. The method of claim 1.

9. moreover, Designing the first support mold; Creating the first support mold; The method of claim 1.

10. 2. The method of claim 1 , wherein the structure includes at least a first structure component having a first curved, non-planar shape and a second structure component having a second curved, non-planar shape that is substantially different from the first curved, non-planar shape.

11. The method of claim 1 , further comprising connecting the first support form to a foundation of an existing building.

12. moreover, placing a second support mold within the first support mold prior to filling the first support mold with the fluid structuring material; filling the second support mold with the fluid support material or with a structural material prior to filling the first support mold with the fluid structural material, and using the filled second support mold to form a hollow interior space within the hardened structural material. The method of claim 1.

13. 13. The method of claim 12, further comprising positioning one or more separator system components between the first support mold and the second support mold, the one or more separator system components spacing the first support mold a set distance from the second support mold.

14. the second support mold is an inner support mold having a first thickness and a first injector and configured to be filled with a fluid-bearing material or a structural material via the first injector; the first support mold is an outer support mold disposed around the inner support mold having a second thickness and a second injector, the first support mold being configured to be filled with fluid structuring material via the second injector such that the fluid structuring material fills a volume between the outer support mold and the inner support mold; each of the one or more separator system components is connected to the inner support form and the outer support form at one or more locations along the inner support form and the outer support form to space the inner support form from the outer support form at the set distance; The method of claim 13.

15. 1. A method of forming a building structure, comprising: forming one or more fluid outlets in a support form comprising a pliable, expandable material; substantially filling the support form with the fluid structural material such that the fluid structural material assumes the complete shape of the support form, and other fluids exit the support form through the one or more fluid outlets during the filling; allowing the fluid structural material to harden within the filled support form, wherein the hardened structural material forms an architectural structure including at least a first structural portion having a first curved non-planar shape and a second structural portion having a second curved non-planar shape that is substantially different from the first curved non-planar shape. method.

16. 16. The method of claim 15, wherein the first fluid comprises air, the fluid structural material comprises a fluid concrete composite, and the hardened structural material comprises a hardened concrete composite.

17. 16. The method of claim 15, wherein the architectural structure forms all or part of a building or statue.

18. 1. A method of forming a building structure, comprising: Inflating the first support mold with an inflation fluid; substantially filling the expanded first support form with the fluid structural material through one or more inlets such that the fluid structural material assumes the complete shape of the expanded first support form, and while filling the expanded first support form, the expansion fluid exits the first support form through one or more outlets; allowing the fluid structural material to harden within the filled first support form, the hardened structural material forming a first portion of the architectural structure; inflating a second support mold adjacent to the first support mold with an inflation fluid; filling the expanded second support mold with a fluid structural material through one or more inlets, and while filling the expanded second support mold, the expansion fluid exits the second support mold through one or more outlets; allowing the fluid structural material to harden within the filled second support mold, the hardened structural material forming a second portion of the architectural structure adjacent to the first portion. method.

19. 20. The method of claim 18, wherein the expanding fluid comprises air, the fluid structural material comprises a fluid concrete composite, and the hardened structural material comprises a hardened concrete composite.

20. 20. The method of claim 18, wherein the first portion of the building structure defines a first curved, non-planar shape and the second portion of the building structure defines a second curved, non-planar shape that is substantially different from the first curved, non-planar shape.

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