Tool design method and device

Abstract

A tooling design that allows for the manufacture of a structure or component in a "one-shot" process in which secondary processes are limited or reduced to a minimum, utilizing automated processes to reduce inaccuracies associated with manual manufacturing and thus reduce the cost of such manufacturing. The tooling consists of two sections, including a buttress (9) and a flange (14), where the buttress fits within the flange. This design produces a structure or component with two internal superstructures that are perpendicular to each other, forming a superstructure that can run the entire length of the final structure. Secondary processes can be applied when the structure is modified to act as a mold. The finished structure or component can be increased in size beyond the initial structure if needed for other finished structures or components, whether they be wind turbine blades or other large structures.

Description

[Technical Field]

[0001] This patent application is for the design of tooling for the production of any large structure or component, and for the sake of clarity, the terms structure and component are used, and structures as defined in this patent are large structures such as caissons, wind turbine blades, aircraft fuselages and wings, full body shells for automobiles and other vehicles, etc. DETAILED DESCRIPTION OF THE INVENTION

[0002] Components are defined as, but not limited to, components for automobiles, aircraft, trains, and the like.

[0003] Additionally, structures such as nacelles, nosecones of trains and aircraft, etc., and various types of residential, commercial and industrial buildings such as factories, dams, silos, etc. are generally defined for components for vehicles, planes, trains, etc., although these structures and components may be interconnected in sections (if necessary).

[0004] Substructures are internal structures of individual tools known in this patent as buttresses / flanges and are defined as structures within the tool or within the final component or final structure, such that the final component and / or structure produced from the tool forms the final component or structure with the structural integrity required for a particular end use. When the internal structures of the tool are interconnected, they form the internal structure or cross section for the final component or structure. This internal structure can be interconnected with the internal structure of adjacent structures and / or components, as shown in this patent.

[0005] Also note I. Internal flanges and internal buttresses, where the internal flanges are sections of the internal structure of the tool and the buttresses fit within the flanges of the internal structure of the tool, and also horizontal and / or vertical internal structure of each section of the tool, where the horizontal structure is connected to the external section of the respective tool and the buttresses are connected to the horizontal structure where the buttresses are at right angles to the horizontal buttresses, the flanges are also connected to the horizontal buttresses, where one flange can move towards the other opposite flange, thereby compressing the incoming buttress and fitting within the flange from the incoming tool (I also uses the terms horizontal and vertical to indicate the orientation of the internal structure in the drawings). There is one buttress on each tool section, there are two.

[0006] Unless otherwise specified below, the flange buttresses, horizontal buttresses, and female flanges within each tool section are all part of each individual tool section that together form the final structure and / or component.

[0007] It should be noted that the final structure or component formed by the tool does not have a buttress only flange, and flanges are only associated with each tool section to form an internal structure or buttress.

[0008] It should also be noted that in some applications, such as aircraft fuselages, at least one of the "vertical" buttresses will be required, otherwise there will be a vertical structure running the entire length of the aircraft cabin, and horizontal buttresses (forming the floor pan) will still be required at the lower "vertical buttress." In this case, the aircraft fuselage has all of the structural integrity designed into the final structure for both sets of tools that form the final structure, and therefore the tools take into account the structural requirements.

[0009] With regard to the shape desired for the final structure, whether it be a cone, a cube, a globe, or other shape, the tooling is designed for the structures and all structures described on pages 1 / 16 and 2 / 16 and corresponding pages of this patent that describe the tooling, and the tooling is also shaped to accommodate both the interior and exterior of the aforementioned structures (e.g., the exterior surface as seen on page 12 / 16, FIG. 15).

[0010] In addition to the above, the final structure or component produced by the tooling can also be utilized as a mold; an example of this utilization is for the production of caissons, where most structures are primarily produced from concrete with steel inserts that act as reinforcement for the concrete; these structures are typically very large, expensive to manufacture, and can take many years to manufacture, in the case of mass reclamation (as an example, land reclamation or creation from the sea) projects requiring hundreds, if not thousands, of these caissons; they are commonly utilized to construct building structures on the seabed, thus the problems involved in constructing and moving these massive structures, some over 10 stories high, by dropping the caissons onto the seabed to act as the foundation for the building structure, a mammoth task of engineering and design; and of course implementation, the tooling design in this patent can produce the final structure that acts as a mold with slight modifications to the tooling, allowing these caissons to be created in weeks instead of months and years at a significantly lower cost. Additionally, due to the lightness of the molds produced from carbon fiber, they can be airlifted or produced on a quayside and taken out to sea and dropped in situ, then concrete can be poured into the mold, reinforcement of the concrete as seen in this patent is done through, but not limited to, carbon fiber poles / solid tubes, in order to overcome the problem of concrete spilling while the mold is being poured at sea, a fabric collar is placed around the outer surface of the mold neck, this collar is tight enough to ensure that the concrete will not spill, and the collar surface is floated above the sea surface by pontoons high enough to ensure that the concrete can be poured into the mold without spilling, see page 8 / 16 which shows heavy dark line diagram 5, see 42 which depicts where the fabric collar can be placed around the top of the mold, this is an arbitrary arrangement and the final arrangement will be in the final design and engineering requirements, the collar is removable and reusable, the mold shown on page 8 / 16 is shown by a square shape but the shape of the mold may be circular (circular) or rectangular,Or it can be any shape that the final design requires.

[0011] The material for manufacturing the structure or component in this patent is based on a woven material so that it is wrapped around both sections of the tool manually or mechanically, and the material needs to cover all exterior surfaces of both sections of the independent tool section. The preferred material is carbon fiber woven or tape for strength and lightness, but is not limited to this material, and the material can be any woven structure or indeed any other suitable material that the final design may require. It should also be noted that the material is wrapped around the tool in its entirety from where no material is needed in relation to the tooling described in this patent and in relation to the final structure or component.

[0012] Once the two sections are compressed together, there are many methods that can be utilized to form the final structure or component (assuming the material is carbon fiber composite), such as compression tooling, vacuum bagging, liquid transfer molding, etc. that can be utilized to form the structure or component by using this patented tooling (assuming the material is carbon fiber composite). For example, when utilizing a compression method, there is an exterior component (tool section) that fits over the entirety of both tool sections and compresses them together, and material within the exterior surface of the tool (and all other portions of the tool section that require material coverage as seen on page 4 / 16 and page 7 / 12).

[0013] It should be noted that there are two compression processes, which may be called for ease of reference Process 1, where the two tool sections and this patent and certain pages / 16, Figures 1 and 2 are compressed together by an outer compression tool, as seen on page 10 / 16, Figure 13b, which focuses on the same type of methodology in Figure 13b, and is also utilized to compress the outer skin wrapped around the final structure or component produced by Process 1, "Compression I" called Process 2.

[0014] Pages 12 / 16 and 13 / 16 state that when compressed and cured (if the material requires curing), as seen in page 10 / 16, Figure 13b, if the material or / sleeve / skin is sandwiched between the inner surface of the compression tool and the outer surface of the final structure or component, this is step 2, and as mentioned above, an example of a compression tool is shown on page 10 / 16, Figure 13b, number 44a, and other processes may be utilized to achieve the same results as above.

[0015] In addition to combining the two tool sections together, Process 1 also compresses the material surrounding the tool, if necessary, in doing so; examples of this are shown on pages 4 / 16 and 7 / 16, no. 24 (material covering the tool). Note that once the material is compressed, the tool design can be such that each separate tool section, as seen in 1 / 16, Figs. 1 and 2, can either be a single process in which the separate tool sections are separated and removed in the direction shown in page 4 / 16, no. 26; the arrows indicate the direction of travel. Note that while the tool is shown vertically, depending on the requirements, the tool orientation can be vertical, horizontal, or any degree of orientation required. Note that I refer to both sections of the tool (unless otherwise noted). I am referring to both sections of the tool. As seen in this patent, once the tool is manufactured by the tool, the tool is removed, leaving each half of the structure or component joined together by the joining of the two halves of the tool (these two halves can be seen in Figs. 1 and 2 and can form the final structure or component, as shown in this patent).

[0016] The tool allows for the creation of buttress structures in the final structure or component, where both horizontal and vertical buttresses can be joined together without localized stress points that can cause failure of the larger or smaller structures, or indeed the structures at these joints.

[0017] The tooling is designed to allow for the formation of structures or components to be created by said tooling, structures, or components where there are no or no secondary processes that allow for the structure or component to be incorporated in a one shot process by ensuring that these structures and components produced by the tooling have internal structures that act as structural portions of the final structure or final component, and therefore no secondary processes need to be performed to form internal structures that reinforce the components where these internal structures form the superstructure (cross section) of the final structure and / or component.

[0018] Large structures such as wind turbine blades are complex and expensive to manufacture and are not always effective where there can be a number of localized stress points, possible bonding of materials issues (e.g., delamination) and structural integrity issues, as well as compression and bending issues, but this patented design can eliminate or minimize these issues, thus optimizing blade design and structure.

[0019] To overcome many of these issues, a "one stop process" (with only a few additional steps required if the tooling is utilized as a mold) is the best possible path to ensuring structural and / or component integrity. As mentioned above, by reducing the process to as few steps as possible, many of these structural issues are overcome and, more importantly, the structural integrity is as critical a factor as possible, sometimes dramatically reducing costs.

[0020] Additionally, the designed tooling will show how these internal structures can be formed and interconnected, and as described above, the interconnection joints will be seamless, integrated, united, formed integrally by the two sections of the tool, and each structure and / or component that forms the structure and / or component after the material is formed around each tool may be part of a section of the structure and / or component and can be interconnected without the need for additional secondary processes to create these internal superstructures (cross sections), and the connections between sections will need to be joined (if the components or structures do not need to be separated) or connected by other means such as bolts or rivets or other joining methods if they need to be removed from each other as needed.

[0021] The primary structure as described in the description referenced above and in the summary below consists of two sets of tooling that mirror each other due to the fact that the buttresses or internal base structures are "offset" relative to the front cross section of the tool buttresses or internal structures. In addition, the flanges are offset relative to the opposing tool internal flanges so as not to impinge on the incoming tool section when both sections of the tool are placed together. The description of the tooling can be seen as follows:

[0022] Pages 3 / 16 through 15 / 16, including page 3 / 16, show either complete structures and / or components made from tooling or part sections, which show how the final structure and / or component is produced, or how they are joined together by a superstructure (formed by tooling) to form a larger structure and / or a component or section of a larger structure and / or component, or a component or section of a larger structure and / or component; Pages 1 / 16, 2 / 16, 4 / 16, 5 / 16 and 7 / 16 show tooling, which makes the structure and / or component; Pages 6 / 16, 5, 8 / 16 and 5 show how the tool may be shaped as a square or rectangle and can come together to form a square or rectangular structure, thus producing the final structure and / or component after each individual segment of the tool (e.g., the segments shown in Figures 1 and 2) is covered with an appropriate material and joined (two tool sections).

[0023] Figures 1 and 7 / 16, Figure 7 show how the carbon fibre in this case covers the outer surface of the structure (for illustrative purposes only part of the material covering is shown on the tool).

[0024] In page 2 / 16, Figure 2b shows a cross section of an aircraft fuselage, as an example, where the upper vertical buttress can be seen in the completed structure or component, as can be seen in pages 3 / 16, 9 / 16, 10 / 16, 11 / 16, 12 / 16, 13 / 16 (a view looking straight on at the structure or component), 14 / 16, and 15 / 16 (note that these pages show a cylindrical structure). In page 2 / 16, Figure 2b shows a cross section of an aircraft fuselage, as an example, where the upper vertical buttress can be seen in pages 11 / 16no. 56 and 58, and in the pages above (from page 14 / 16). Apart from this, Figure 17 does not show either the vertical buttresses above or below the horizontal buttresses, as can be seen in Figures 13, 10 / 16, 13b, 11 / 16, 14, 12 / 16, 15 (components shown vertically) and 13 / 16 pages, a lower buttress is not required and Figure 16 remains, as shown in Figure 2 / 16, 58a, which is designed to incorporate the interior requirements of the aircraft, such as undercarriage, electronics, cargo, etc., and the portholes shown do not represent cabin or fuselage windows.

[0025] 54a and 58a are for illustrative purposes only.

[0026] Page 2 / 16, Fig. 1a shows Fig. 2b, Fig. 1a is the same tool section on page 1 / 16, Fig. 1 shows that on page 2 / 16, Fig. 2b shows that on page 1 / 16, Fig. 1 is the same tool section with the flanges not shown in tool Fig. 1a, Fig. 2b shows that on page 1 / 16, Fig. 2, No. 9 (assuming 9 is a vertical buttress), no lower vertical buttress is required and if 9 is a vertical buttress, then by rotating to the left in this case, if the tool sections when combined are rotated to a horizontal orientation or rotated to the right to be in a horizontal orientation, then the vertical buttress not required is not 6, otherwise the design of the tool section is the same as the design on page 1 / 16, Fig.

[0027] Page 8 / 16, Figure 5 differs from the above, this shows Figure 5, No. 37a, whereby the partition Figure 9, No. 36 is placed among the components Figure 5, No. 31, Figure 10, forming a structure as shown in Figure 9, and placed in Figure 10, this tool can act as a mold for concrete for the production of caissons or other large structures, but creates structures not limited to such large structures, in the case of caissons the mold is not removed from the concrete but remains in place, also forming reinforcement and protecting the concrete.

[0028] Page 8 of 16, Fig. 5, No. 42 showing heavy dark lines, a fabric collar can be placed around the top of the mold.

[0029] Page 1 / 16, fig. 1, no. 3 shows a double-headed arrow indicating the direction of movement of the two sections of the tool, and how the two horizontal buttresses (to save disruption of the horizontal buttress structure) fit together to produce a structure or component, and the two horizontal buttresses (to save disruption of the horizontal buttress structure) are moved towards each other by suitable external means as described in this patent, thus sandwiching the material placed on the tool as shown in page 4 / 16, fig. 1, no. 24, and page 7 / 16, 24 indicates the part of the tool covered by the material (in this case, carbon fiber fabric).

[0030] The surfaces of the horizontal buttresses face each other.

[0031] The material is compressed by the coming together of both tool sections where the horizontal and vertical buttresses are covered by material, and thus when tool sections Figure 1 and Figure 2 come together the tool sections can form the final structure and / or component.

[0032] Page 1, Fig. 1, No. 1 and Fig. 2 show two halves of the tool for making the structure and / or component, 49 in Fig. 13 shows the extended lip or buttress as seen in Fig. 13, 49 in Fig. 13 shows that the buttress angle is a right angle as seen in Fig. 13, this is for illustrative purposes only, this edge will not affect the final structure and / or Page 3 / 16, Fig. 3, No. 9 / 16, Page 10 / 16, Page 11 / 16, Page 12 / 16, Page 13 / 16 As shown in Page 6 and Page 15 / 16, the final structure and / or component produced from the tool can be either right-angled or curved (rounded) to any extent (see Page 15 / 16, lower vertical buttress not shown). As shown in Pages 3 / 16 and 10 / 16-15 / 16 (apart from Page 14 / 16), two sections are joined together to form the final structure or component. However, in these drawings of the final structure or component it is shown to be a cylinder. Although shown, the tool may be conical, square, oval, globe, etc., and therefore the internal structure forms the cross sections shown in this patent horizontally and vertically, particularly pages 9 / 16-15 / 16 (Fig. 18 does not show the lower vertical buttress, and Fig. 18 does not show the lower vertical buttress) away from page 14 / 16, and the tool that produces these sections and the final shape of the final structure and / or component (the tool shown in Page 14 / 16) is correspondingly shown in Fig. 18, NO. 84, Fig. 18, Fig. 84, and Fig. 18. As shown in the heavy dashed lines in Figure 84, the shape of the structure and / or component to be shaped / designed and compensated to produce any of the above mentioned shapes is a cone shape, this clearly indicates that this is when both the internal buttress and the flange of each tool are tapered to form a cone shape, but this is similar to the above mentioned shapes such as globe or cube or cylinder, please note that the base of Figure 2 is not shown Page 1 of 16, Figure 1, 9 section (buttress) is shown in Figure 2, No. 14, (No.14 is also part of the horizontal buttress and is perpendicular to the horizontal buttress) and does not move inside the flange.

[0033] If the 146 buttresses are not fitted within the flanges in Figure 1, No. 15 and 14h (No. 14h is a movable flange), then these two sets of flanges are 14 / No. 14h and No. 15 / No. 14h and are part of the horizontal buttresses Figure 1 and Figure 2 No. 5 (flange no14h is connected to the horizontal buttress as shown in Page 5 / 16, Figure 2a and is perpendicular to the horizontal buttress) Further, in Page 1 / 16no6 and no9, as can be clearly seen in Page 3 / 16, Figure 3, the buttresses are perpendicular to their corresponding horizontal buttresses and are also part of the horizontal buttresses.

[0034] 16 in Figure 1 shows the cutout for buttress number 9, which in this case allows buttress number 9 to fit within the opposite tool Figure 2, which in this case allows buttress number 9 to fit onto the incoming male section shown at number 11, which in this case Figure 2 allows buttress number 6 to fit onto male section number 11 in Figure 1, the male section 11 being the same for buttress number 6 is not shown on Pages 1 / 16, Figure 2 but can be clearly seen on Page 3 / 16, Figure 3 of the finished structure or component produced by the two halves of the tool (Figures 1 and 2) coming together.

[0035] 15, section 3b, 63, to allow the male section of the incoming tool as shown in FIG. 15, section 12 / 16 to be cut and enter the female section of FIG. 12 / 16 as shown in FIG. 15, section 3b, 63.

[0036] Internal structure, Pages 1 / 16 Fig. 1 No. 15 / No. 14h, and No. 14 / No. 14h show flanges for accommodating No. 6 and No. 9 buttresses. Page 3 / 16 Fig. 3 No. 9.

[0037] 1920 indicates the vertical buttress of the finished structure and / or component, the horizontal buttress on page 3 / 16 is shown at 17, not 17 in Figure 1, buttress number 9 is part and indicates the internal buttress of the final structure or component that forms a bridge between the two components formed by the tools (seen on page 1 / 16, Figures 1 and 2) when the tools are placed together to form the final structure or component.

[0038] Page 3 of 16, Fig. 3, 21 shows the interior horizontal buttress of Fig. 2 (buttress Fig. 2, 6 is a part) of the completed structure or component.

[0039] Page 3 / 16 also shows the finished component, as do pages 6 / 16, 8 / 16, and 9 / 16-15 / 16 (page 14 / 16 shows only horizontal buttresses where in some cases vertical buttresses may not be required). The buttresses in the tool section of Figure 1 create the structural part of the final structure or component, allowing pages 1 / 16, 1, 9 and 2 to slide between the two respective female flanges forming a fit that allows the material covering the buttresses of No. 15 and No. 9 to be tightly compressed against the inner walls of the female flanges of No. 15 and No. 14, where buttresses No. 6 and No. 9 are movable to compress the buttress, once buttresses No. 6 and No. 9 traverse the entire depth of the corresponding flanges No. 15 / No. 14h and No. 14 / no.

[0040] 14h are each h, and the tools Figure 1 and Figure 2 are connected together to form the final structure and / or component.

[0041] Thus, the final structure and / or component has the final internal structures formed by the tool sections without any secondary processes required to produce those internal structures.

[0042] Page 3 / 16, Fig. 3, No. 19 and No. 20 show how the vertical buttresses, Page 1 / 16, Fig. 1, No. 9 and No. 6 respectively connect to the structural Fig. 1, No. 4 and are part of the internal structure of the completed structure and / or component. In addition, the internal structure is also part of the horizontal buttresses, structural Fig. 1, No. 5. Fig. 1 and Fig. 2 show how buttresses 9 and no. 6 fit within the flanges of No. 14 and No. 14h and No. 15, No. 14h respectively, where Page 1 / 16, Fig. 2 is not.

[0043] 6Flanges shown on either side of the buttress in Figure 2 No. 6 fit inside flanges in Figure 1, No. 15 and No. 14h, and flanges in Figure 1, No. 9 do not fit inside flanges in Figure 14 and No. 14h.

[0044] 14 It must be noted that what would be on either side of the buttress in Figure 2 No. 9 is what is shown on page 3 of 16 is the finished component. However, the term buttress remains the same whether it is the tooling or the final structure and / or component. It must be noted that the final structure or component is only a part of the tooling and does not have a flange associated with it or when the tools come together to form the final structure or component, it does not have a flange.

[0045] Page 3 / 16, Fig. 3, No. 17 also shows two horizontal buttresses joined together, as shown in Fig. 1 and Fig. 2 and No. 2 / 16, Fig. 1a and Fig. 2b, joining two independent tooling structures on Page 1 / 16, Fig. 1 and Fig. 2 and No. 2 / 16, Fig. 1a and Fig. 2b, as also shown in Fig. 9 / 16, Fig. 13, No. 10 / 16, Fig. 13b, Page 11 / 16, Fig. 14, as shown in Fig. 5, Page 3 / 16, Fig. 6 and No. 8 / 16. 16, No. 16 / 16, Fig. 17 and 18 / 16, Fig. 19, No. 20 / 16, Fig. 21, No. 22 / 16, Fig. 23, No. 23 / 16, Fig. 24, No. 24 / 16, Fig. 25, No. 25 / 16, Fig. 26, No. 26 / 16, Fig. 27, No. 27 / 16, Fig. 28, No. 28 / 16, Fig. 29, No. 30 / 16, Fig. 31, No. 31 / 16, Fig. 32, No. 32 / 16, Fig. 33, No. 33 / 16, Fig. 34, No. 34 / 16, Fig. 35, No. 35 / 16, Fig. 36, No. 36 / 16, Fig. 37, No. 37 / 16, Fig. 38, No. 38 / 16, Fig. 39, No. 40 / 16, Fig. 41, No. 41 / 16, Fig. 42, No. 42 / 16, Fig. 43, No. 43 / 16, Fig. 44, No. 44 / 16, Fig. 45, No. 45 / 16, Fig. 46, No. 46 / 16, Fig. 47, No. 47 / 16, Fig. 48, No. 48 / 16, Fig. 49, No. 50 / 16, Fig. 51, No. 51 / 16, Fig. 52, No. 52 / 16, Fig. 53, No. 53 / 16, Fig. 54, No. 54 / 16, Fig. 55, No. 55 / 16, Fig. 56

[0046] In Figures 3, 23, the buttresses meet the external structure of the finished structure or component formed by the tool (opposite meeting of the buttresses with the internal structure of the finished structure or component), and are also shown on page 8 / 16, except on page 14 / 16, where only horizontal buttresses are shown on page 15 / 16.

[0047] Page 1 / 16, Figure 1, No. 12 shows an illustration of the male section of the secondary structure being able to enter the female section of the primary structure as seen on Page 1 / 16, Figure 1, No. 11 (male section), and also on Page 12 / 16, Figure 15, No. 63, and Page 14 / 16, Figure 17, No. 71. In this patent, the primary and secondary structures are defined as Section 3a (primary structure) and Section 3b (secondary structure). These cues allow the horizontal substructures or buttresses to enter the secondary structure or components to allow the completed structure or component to join and connect these structures or components. These cues can also be clearly seen on Pages 2 / 16-15 / 16 (away from Page 13 / 16), and on Page 12 / 16, Figure 15a, No. 13, and Page 14 / 16, Figure 17, No. 74, where the absence of the vertical buttress on Page 14 / 16 is shown.

[0048] For clarity, the cube (not to scale) houses the incoming male portion of any secondary structure or component whose secondary structure or component can be seen on page 12 / 16, Figure 3b, No. 63, and Figure 3b is a secondary structure that can also be seen on pages 11 / 16 and 14 / 16.

[0049] Page 4 of 16, Figure 4, No. 26, arrows indicate the direction (vertical) of tool movement in removal from the final structure and / or component, and the final method of removal is determined on the final design of the tooling.

[0050] 4 / 16, Fig. 4, 25, but the top edge / surface should not be covered to allow the tool to be removed from the component, and it should be noted that the tool may be removed by other methods depending on the final design of the tool to be moved vertically away from the structure or component if the structure or component is vertical, or horizontally away from the structure or component if the structure or component is horizontal, or at any other degree from vertical or horizontal.

[0051] 4, No. 24 shows how the outer surface area can be covered with either a woven material or other suitable material. As shown, all outer surfaces should be covered apart from open or cut-out areas. Note that in this Figure 4, No. 24, not all outer surfaces are covered and the coated surface only shows the percentage of the outer surface area that is covered; this is purely for illustrative purposes and shows that the open and cut-out areas will not be covered. Both sections of the tooling outer surface will be covered as well. For structural reasons, the buttresses and required surfaces may be covered with a more structurally robust material such as carbon fiber, and then the final outer skin / sleeve may be covered with a lower cost material such as fiberglass or high-strength canvas. Note that in some cases, an outer skin / sleeve may not be required, as a single section such as Figure 3a may represent a finished structure or component that does not need to be attached to any other secondary structures and / or components. Note that if several sections are interconnected, a sleeve / skin may also not be required, depending entirely on the final design requirements.

[0052] Figure 2a shows how, if necessary, the buttresses can be moved perpendicular / 90 degrees to the incoming buttresses shown in Figure 1 / 16, Figures 1 and 2, Nos. 9 and 6, allowing the entire flange to compress against the incoming buttresses Nos. 6 and 9; the flanges Page 5 / 16, Figure 2a, No. 14h, can be connected by "pistons" as can be seen in 14b; these pistons connect the body of the tool to the movable flange No. 14h in Figure 2a, as can be seen in Figure 2a; the bolsters, not shown in 14c, are connected by bars (or suitable system) as shown in 14g, and the bolsters move both towards and away from the tool; 14e shows the bolster in an open position, as is the horizontal flange, and No. 14f shows the bolster in a closed position, similar to the horizontal flange when not closed.

[0053] 14f. No. 14d shows the bolster in the open position in the outer tool section, which can be seen on page 1 / 16, Figures 1 and 2, No. 4, and on page 2 / 16, Figure 2, No. 4, which can be seen in an enlarged view on page 5 / 16, Figure 2a, and also shows the bolster in the outer tool section as shown on page 1 / 16, Figures 1 and 2, No. 4 (outer tool section). When the bolster is closed (flange 14h) and moves the required distance towards flanges 14 and 15, the double arrows shown in Figures 2a and 14i indicate the direction of movement in which the flange compresses the material (carbon fiber in this case) to the required pressure between the flange and the vertical buttress, so that the carbon fiber material can be heated and cured. Once cured, the flanges can be separated by the bolster when they move to the open position, opening and closing the buttress. It should be noted that a ratchet mechanism can be designed into the outer tool section or a high-pressure air system, or other methods currently available.

[0054] It should be noted that page 5 / 16, Figures 2a and 14a show the gaps through which the bolsters move, and that the bolsters are in guides (not shown) which are under pressure as they move to their closed position by a suitable mechanism within the guide. The bolsters (not shown) are pushed open as seen in page 5 / 16, Figure 2a, no. 14c and remain in the open position until forced into the closed position by a suitable mechanism such as a ratchet or high pressure air system which is an integral part of the outer wall of the tool. It should be noted that the flange can be partially seen in page 5 / 16, Figure 2a, no. 14h. No. 14k shows a two headed arrow indicating both the direction of movement of the bolster, with the double arrow indicating the direction of movement of the bolster from open to closed position and vice versa. Figure 2a, no. 14c shows the outer wall of the tool as seen in page 5 / 16, Figures 2a and 2, no. 14h.

[0055] The mechanisms shown in Figure 2a on page 5 of 16 are shown for illustrative purposes so that the reader can see how the mechanisms that move flange 14h function; note that in the final design, these mechanisms will be hidden from the top and side views and will not impinge on the cover of the tool using the necessary material. Note that the connecting bars between the buttresses will be visible, and that these connecting bars may also be separated to allow the finished structure or component to be removed from the tool. As previously mentioned, movement of flange 14h may be deployed by other suitable means that will be incorporated into the final tool design.

[0056] Page 8 / 16, Figure 5 shows a structure produced by tooling for a building that could be a rapidly manufactured low cost housing or warehouse or actual hospital or other structure, there is a great need for cheap, quick and affordable housing within the UK and the main structure of a building could be manufactured globally in one shot process, where all the plumbing, electrical equipment could be added as a secondary process, Currently this patent looks at the maximum size of the structure due to rapid tooling (which may change in the future), but as seen in this patent, the smaller heights of each final structure could be joined together to reach an estimated height of 25 metres tall, this would give a total surface area of ​​25m x 25m = 625m of floor, the height could be 3m so the building could be split level, giving a ceiling height of 3m (or larger or less as needed) and if utilized for housing each level (in the vertical direction) could be 625 sq ft apartment This means that each structure can accommodate 40 people per floor, or 320 people per structure. 10 structures would accommodate 3,200 people, or 100 structures would accommodate 2,000 people, enough to provide immediate containment in a disaster zone such as an earthquake or flood or any other disaster zone. They can be produced in time and shipped if they are made at a height of 25 meters, or airlifted if they are made at a height of 9 meters somewhere in the world if assistance is needed. Because tooling can be made in any size up to 25 meters as mentioned above, the tool width and tool height can be manufactured to build the finished structure (in this case, the housing), so that the finished structure can fit within a rapid mode of transportation such as an aircraft.

[0057] These can be semi-permanent or permanent structures, and if permanent they can be clad on the outside to fit in with the natural surroundings (note that carbon fibre has to be clad on the outside and inside to protect and insulate the building / structure), thus in order to fit in with the natural surroundings as mentioned above the structure can be clad in timber, as an example in countries where houses are mainly built from timber.

[0058] Door and window passages can be introduced as needed, and floor space can be divided by removable walls to make rooms larger or smaller as required. In the case of housing, a relatively small space is required, whereas in the case of a warehouse or hospital, a larger open space may be required, but all structures can be interlocked as needed, both vertically and horizontally, so that tall buildings can be produced quickly and at low cost, particularly in areas prone to earthquakes, or where buildings are not constructed to a high level of structural integrity which would lead to skyscrapers or tall building collapses.

[0059] Page 8 of 16, Figure 5, No. 37 shows further possible buttresses, and No. 37a shows cutting. Additional buttresses can be produced by the tool if required for greater structural integrity / space division.

[0060] Page 6 / 16, Figure 5 NO.28 shows a male section, which can be set on a foundation of corrugated sandwich material (if located in an earthquake zone) or on a foundation of other method where the material or foundation is robust enough to hold the complete structure but can absorb further tremors. The entire structure including the corrugated sandwich structural material (or other suitable structure available in technology) can then be set in concrete or other suitable material.

[0061] Page 6 / 16, Fig. 5, No. 30 shows the extension of this buttress which in this case may extend laterally so that buttress 30 can enter the adjacent structure of Fig. 6, and the buttress of Fig. 5 would be connected by suitable means to the buttress of Fig. 6 as shown at buttress of Fig. 6, Fig. 18, No. 82. It should be noted that the buttress of Fig. 5, Fig. 18, No. 82 is shown as partially entering the adjacent structure Page 6 / 16, Fig. 6 and the transverse portion of the buttress shown in Fig. 6 does not show the complete structure of the adjacent structure.

[0062] Page 6 of 16, Figure 5, No. 27 shows further possible buttresses, with dashed lines indicating possible positions of further buttresses and dashed lines indicating the current position of the buttresses.

[0063] FIG. 6, NO. 32, PAGE 6 / 16, FULL STRUCTURE FIG. 6 (PARTIALLY SHOWN) CAN BE CONNECTED TO ANY OTHER FULL STRUCTURE / STRUCTURES AND / OR COMPONENTS.

[0064] Page 6 / 16, Figure 6, No. 33 shows the vertical buttress of an adjacent structure or component, the buttress being clearly seen on Page 3 / 16, Figure 3, No. 20.

[0065] The complete structure or component is shown on page 6 / 16, Figure 5, No. 31.

[0066] Page 7 / 16 shows two sections of the tool, (Fig. 7) shows the partial outer surface covered with material, as also shown in Fig. 4 / 16.

[0067] Page 8 / 16, Figure 9 shows a very simple cross joint (not to scale) in which there is no divider Figure 9.

[0068] 36 Intersecting buttresses forming a cross shapePage 8 / 16, Fig. 9 is shown with a separation showing how the buttresses joinPage 6 / 16, Fig. 5, No. 27 shows the buttress before the divider is placedPage 8 / 16, Fig. 5, No. 37a shows the cutaway in Fig. 1 and No. 6 shows the buttress (not shown in Fig. 37aPage 1 / 16, Fig. 1, No. 6) so the dividerFig. 9, No. 36 is the divider forming a "cross joint" as shown in Fig. 9, Fig. 9, No. 34 6, CrossDivider is not shown Depending on the structural strength required, or in the case of a caisson, there may be several divider beams (note that dividers should not be confused with buttresses) arranged in the complete structure Diagram 5, No. 31, where it is noted that the whole structure acts as a container / mold for the concrete to be poured into it For example, if the caisson is 25 meters by 25 meters base and 25 meters high, the dividers may be 2.5m by 2.5m to form cells of 25m. The grid sections, when viewed in plan, form 2.5m x 2.5m x 25m cells, like a chessboard, and they are spaced, for example, 2.5 meters apart (the divisions will depend entirely on the structural engineer's calculations and requirements). The number of buttresses can also be increased to accommodate the number required, which in this case would be eight if the divisions are 2.5 meters apart. The number of divisions and the amount of buttresses required will depend on the final design and required structural integrity of the final caisson, as discussed above. Structural Diagram 5, No. 31; Complete Structure, Diagram 5, is for the caisson, and not only the mold for the caisson but also the lattice structure used to give the caisson the structural strength and required structural integrity. The structural strength of carbon fiber replaces steel and has all the advantages (not expanded upon in this patent) that come from replacing steel whenever possible.

[0069] Page 8 / 16, Figure 9 shows the cross partitions shown in Figure 12, Figure 12 No. 39 (internal cross-sectional 3D view of Figure 10) shows 3D sections of a grid created by carbon fiber composite poles or other suitable material placed within the structure Page 8 / 16, Figure 5, and finished structure Page 8 / 16, Figure 5 shows each section (in this case 100) of the column created by the partitions within the tool of Figure 5, Figure 11 shows a side cross-sectional view, and Figure 11, No. 38 also shows a side view of the grid created by carbon fiber composite poles or other suitable material, including but not limited to, columns of carbon fiber composite poles or other suitable material, as well as ...

[0070] 1 These provide structural strength to the concrete.

[0071] 2These connect the concrete columns and in this example the concrete columns are all interconnected thereby giving the concrete columns added structural strength as each concrete column is separate and if one fails it does not affect the other columns and therefore the whole structure remains extremely stable an added benefit is that the whole concrete structure is surrounded by a carbon fibre composite structure thus protecting the concrete.

[0072] Page 8 / 16, Figure 9, no. 35 also shows a carbon fiber composite pole or other suitable material as a cross-sectional view of one of the section grids, the grid being visible by only two sides, the other two sides being shown open for illustrative purposes only.

[0073] The holes for the carbon fiber composite or other suitable material can be cut by a laser or water jet cutter or any other suitable means. The holes have re-formed matings with the poles, and the poles are bonded to the holes by a suitable bonding agent if necessary. The number of carbon fiber composite poles or other suitable material and their respective distribution within the "cells" created by the dividers and buttresses is determined by a structural engineer and is not part of this patent. Correspondingly, the carbon fiber composite poles or the combination of materials to make the carbon fiber composite poles or other suitable material are again subject to final structural analysis and design.

[0074] Page 9 / 16, Fig. 13, NO. 43, where the buttress is shown in a horizontal position (Structure Page 9 / 16, Fig. 13 shows the entire structure and / or components in a horizontal position).

[0075] The dashed structure on page 9 / 16, Figure 13, No. 48 shows not only the structure or component formed in Figure 13, but also parts of pages 10 / 16, 11 / 16, Figure 14, No. 58, Page 12 / 16, Figure 15, No. 59 (No. 59 shows the cross section formed by horizontal and vertical buttresses), 13 / 16, Figure 16, No. 66, Page 14 / 16, Figure 17 (No. 17 does not show the vertical buttresses) and page 15 / 16, Figure 18, but these pages do not show that the components depicting each section of the tool may have internal structures positioned so that the connecting structure or component's internal structure (buttress) can move within the internal structure (buttress) of two vertical and horizontal internal structures, for example, as can be seen in pages 11 / 16, Figure 14, No. 56 and No. 58, where the internal structure (buttress) can move a distance.

[0076] 3a where a buttress overlaps the internal buttress of the connected secondary structure or component is connected to FIG. 3b where a buttress overlaps the buttress of the connected section where FIG. 3a is connected to FIG. 3b where FIG. 3a is connected to FIG. 3b and No. 80 shows the overlap and connection of vertical buttresses in section FIG. 3a and section FIG. 3b The distance of buttress overlap, whether vertical or horizontal, will depend on the structural requirements of the final design of the final structure or component as a whole.

[0077] The horizontal internal structure where the buttresses are offset from the center shown by dashed lines is not shown on Page 9 / 16-Page 15 / 16 but is partially represented by the heavy black lines of the final structure and / or components. Attention is drawn to Pages 9 / 16 to Page 15 / 16 where it is noted that the structure is described and shown as a cylinder for illustrative purposes and may be conical or tapered like a turbine blade as designed to suite the application.

[0078] Page 9 / 16, Fig. 13a, which shows how No. 53 overlaps No. 47, and the horizontal buttress is also shown in Page 14 / 16, Fig. 17, Section Fig. 3a, No. 72 fits into Section Fig. 3b, No. 70.

[0079] Page 9 / 16, Figure 13a No. 44 does not show the outer shell or sleeve.

[0080] Page 9 / 16, Figure 13a, number 50 shows a vertically oriented internal buttress flush with the outer skin or sleeve.

[0081] Page 1 / 16, Figure 2, section 6 (buttress) fits into the two flanges shown in Page 1 / 16, Figure 1, section 15 / 14h, and the gap between them to allow buttress No. 6 does not fit into 7 in Figure 1. In addition, the opposite section in Figure 1, buttress No. 9, fits into No. 14 / 14h in Figure 2, said two flanges are shown as Nos. 14 and 14h, and as shown in flange No. 15 / 14h, it can be seen that these two buttress sections are offset relative to each other so that they do not collide with each other when the two halves of the tool combine are combined to make one single tool, and the final structure or component can be manufactured.

[0082] It should be noted that the flanges shown by the double arrows in Figures 1, 15, 14h, and 16, which are also shown in Figures 1, 8, and 2 and which show the flange portions by dashed lines, should not be confused with the flange portions shown by Figures 1, 15, 14h, and 16, which show how they fit within their respective sections.The flanges are not shown in dashed lines to show the flange profile within the tool sections in both Figures 1 and 2, and 8 is the same flange as the flange.

[0083] For clarity, it can be seen in page 3 / 16, Fig. 3c, separation of buttress Fig. 3, no. 9, (no).

[0084] 19 Figures 3 and 3c are the same buttresses as in Figures 3 and 3c, except that No. 9 fits into flanges Figure 3c, No. 14 and No. 14h, which can be seen on Page 1 / 16, Figure 2, Nos. 14 and 14h, and Page 2 / 16, Figure 2.

[0085] Page 1 / 16, Figure 2, No. 10 shows the gap where the buttress enters the wall of the tool. As can be seen in Page 13 / 16, Figure 16, Final Structure or Component, the inner buttress is flush with the wall of the final structure and / or component and the inner surface of the sleeve / skin can be seen to be bonded to the outer surface of the finished structure or component (the inner surface is the surface that faces the surface of the final structure or component). Note that Figure 16 shows the final structure and / or component covered by the sleeve / skin.

[0086] Page 1 / 16, Figure 1, No. 11 shows what may be described as a male section of the tool, so as to allow one finished structure and / or component produced by the tool covered with the required material such as carbon fiber or other suitable material to fit within a second finished structure and / or component, as shown in Figure 15 of Page 12 / 16, where section 63 shows the male section of Figure 3b fitting within the female section of Figure 3a, also seen on pages 11 / 16, 12 / 16; 13 / 16; Figure 16 shows a telescopic view of the two structures or components when they are joined together, while pages 14 / 16 and 15 / 16 show the two components to be joined together after they emerge from the tool to form the required structure or component, again the material from which these structures and / or components are produced will be determined by the final design and technical as well as structural requirements of said structures and / or components, it being noted that the preferred material is carbon fiber.

[0087] All internal structures are the diameter of their corresponding structure or component unless the internal structure is partially cut away to allow the secondary structure to be joined to the original structure, cues are shown on page 1 / 16 to page 14 / 16. As shown in page 12 / 16, Fig. 15a, No. 13, the cutout is shown separated, page 13 / 16, page 3, page 18, page 9 / 16, Fig. 13, page 52 shows the cutout to allow movement to Fig. 3b, page 14 / 16, page 18, page 9 / 16, Fig. 13, page 52 shows the cutout to allow movement to Fig. 3a, page 14 / 16, this can be clearly seen in Fig. 18, page 81, the cutout on the horizontal buttress and Fig. 3b, page 14 / 16, Fig. 17, No. 74a, in Fig. 3b, Fig. 3a allows movement to Fig. 3b, as shown in page 14 / 16, Fig. 73, and as shown in page 15 / 16, Fig. 18, buttress No. 81 of Fig. 3a can be seen in Fig. 3b, Fig. 3a is shown connected to Fig. 3b.

[0088] Page 9 / 16, Fig. 13, No. 51 shows a cutout to allow the vertical structure Page 15 / 16 Fig. 18, No. 81 to pass through, as shown in Fig. 18, Fig. 79.

[0089] Page 9 / 16, Figure 13, No. 47 shows horizontal internal structures (buttresses) such as No. 56 and No. 58 which show how they can seamlessly fit into internal structures or buttresses formed in cross section by both vertical and horizontal buttresses interconnected to traverse the length of the structure Figure 3a and Figure 3b, the vertical internal buttresses of Figure 3a traverse any length of the internal Figure 3b, the final length being defined by the required structural requirements of the final structure and / or component, as can be seen in Page 11 / 16, Figure 14, Section Figure 3a.

[0090] 56 In any length of Figure 14, section Figure 3b, 58, where the number 56 cannot be seen by both the dashed line crossing the vertical buttress in section Figure 3b and the dashed line crossing the vertical buttress in section Figure 3b, the two buttresses in sections Figure 3a and Figure 3b may be fastened or joined by any suitable methodology.

[0091] Page 9 / 16, Figure 13, No. 46 shows the internal structure of Figure 14, page 11 / 16, Figure 13 is a horizontal buttress as seen on pages 11 / 16, 58b and 45, Figure 13 is shown as being centered, for example, this is for illustrative purposes only, it can be "offset" to design specifications such as an aircraft floor pan, the structure needs to be offset from the center position as shown by the dashed line in Figure 13 No. 47 (center position).

[0092] Page 9 / 16, Fig. 13, Fig. 3a, buttress no. 45 overlaps with the internal structure or buttress of the structure, or the cross-section of Fig. 3b, Fig. 47 (not to scale) not shown here, but to be joined (by external fasteners or adhesive) to a second such structure and component as shown in Fig. 14, as shown in No. 11 / 16, Fig. 14, NO. 58, Figs. 3a and 3b form a finished structure and / or component (material structure or component not shown), for example, as shown in No. 12 / 16, Fig. 15. It should be noted that depending on the sections such as section 3a and section 3b which may be part of the final structure and / or components shown joined together by suitable means to form a single unit, the positioning of the internal structure as shown in Fig. 17 of page 14 / 16 may be above or below page 14 / 16, Fig. 17, No. 70, but the function of combining (in this case horizontal buttresses) remains the same. Thus, the positioning of Page 9 / 16, Fig. 13, ether above 45 of page 9 / 16, Fig. 13, no. 47, or below No. 47, purely depends on the final design.

[0093] Page 9 / 16, Figure 13, No. 48, dashed internal buttress structure shows only the structure formed as in Page 3 / 19, Page 6 / 16, Page 8 / 16-Page 15 / 16. Page 14 / 16, Figure 17 does not show the vertical buttresses from Page 3 / 16 and Page 9 / 16 to Page 15 / 16. Structures and / or components can have internal structures arranged such that two structures and / or components can be combined by their respective internal structures as shown in this patent (formed by combining two separate tools according to Page 1 / 16, Figures 1 and 2 to form one larger structure and / or component). Internal buttresses of one structure and / or component are shown, for example, in Page 9 / 16, Figures 13 and 13a, Figures 13 and 13a, No. 11 / 16, Figure 14, No. 58, Page 14 / 16. As can be seen in Figure 17 (only the horizontal buttress position is shown on page 14 / 16) and pages 15 / 16, Figure 18, there may be an overlap with the internal buttress of a second structure or component, however as described in this patent, the overlap of the internal buttress of the structure and / or component in this case the internal buttress of sections Figures 3a and 3b may be 100% of the length of the structure or component and may be extended if necessary to interconnect with other sections as shown. Note that the shape of the final structure and / or component is designed as a cylinder for illustrative purposes only but may also be conical or tapered, like a turbine blade designed to fit the application.

[0094] Figure 13a on page 10 / 16 shows that when the two halves of the outer tool half-cylinder are joined together, the weight of the two halves (or by external pressure) compresses the material, thus hardening the material covering the final structure or component, and if the material requires heating, a suitable mechanism is designed to heat the tool, which is not part of this patent, and the process of joining the two halves of the outer tool half-cylinder is shown in Section I of the patent.

[0095] It should be noted that Figure 13b on page 10 / 16, No. 44b, this section of the outer tooling system can be moved to compress the material covering the final structure or component, and the two parts of the tool come together to form the final structure and / or component shown in this patent. The two separate structures or components formed by each tool section as seen on page 1 / 16, Figures 1 and 2, to form one larger structure and / or component. It should be noted that each separate section as seen on this page and this patent and Section Figure 3a and Section Figure 3b is covered with the required material (if needed), such as carbon fiber, and once the two sections are produced and covered with the desired material, they are compressed by the outer tool as seen on page 10 / 16, Figure 13b, until the material is hardened (if the material requires hardening), thus producing the final structure or component. Figures 3a and 3b The two completed structures of Figures 3a and 3b, for example, as seen on page 12 / 16, Figure 15, may be joined together by their corresponding buttress and male sections, as seen on page 12 / 16, Figure 15, No. 63, which is the male section of the structure, or part that goes into section Figure 3a to form a further structural joint, as seen in Figure 3b. Note that the male of Figure 3b has a clamped fit or is close to a clamped fit, which allows the technology to work when it goes into section Figure 3a to join both Figures 3a and 3b. The heavy black lines shown on Page 12 / 16, Figures 15 and 15a partially indicate where materials covering the final structure and components will form the final structure or component, which may also be defined as the final structure or final product (materials may be added to the final structure and / or component as needed, but are not shown in this figure). Note that Figure 15 shows the final product.

[0096] Page 10 / 16, FIG. 13B, double arrow at number 44c does not indicate the direction of movement of this portion of the outer compression tooling, 44a and 44b are not shown. Note that this outer compression tooling design is for illustrative purposes only and shows how material surrounding a final structure or component is compressed to form the final structure or component by compression of the material of the structure or component, and the same method can be used to combine two tool sections to form the final structure or component.

[0097] It may not be necessary for the final structure or component to have an outer sleeve / skin, this depends purely on the final design of the structure or component.

[0098] Page 12 of 16, Fig. 15a shows a cross section of a buttress whether or not this cross section I used buttress number 9, as can be seen in page 1 / 16, buttress number 9 in Fig. 1a, how the buttress, when coated with the appropriate material, enters the cut-out section of the outer tool and how the buttress before inserting the buttress into the outer section of the tool, in this case represented by buttress number 9, can be seen in page 1 / 16, Fig. 10, and Fig. 2 / 16, Fig. 21.

[0099] Also, Page 12 / 16, Figure 15b shows a cross section (No. 10), buttress No. 9, and a front view of flanges No. 14 and No. 14h, 14h, which are moving flanges so as to compress the material (as seen in Page 1 / 16, Figure 1, No. 24) between the flange and the buttress (the material is seen in Page 5 / 16, Figure 2a and described in this patent).

[0100] Figure 15a, No. 10, where No. 10 indicates the gap (Figure 2) where buttress No. 9 enters and is flush with the inner surface of the outer material or sleeve / skin, where as mentioned above the white line is only to indicate where the buttress enters and joins and is bonded by a suitable adhesive (glue) to the final material described as the outer material of the corresponding tool section formation (e.g. once both tool sections are joined together as seen in Figures 1 and 2), Figure 15, No. 64 and for illustrative purposes No. 64 is also a white line as shown in Figure 15a, No. 10, which indicates the edge of the outer material of the final structure and / or component.

[0101] It should be noted that FIG. 22 shows how the final outer sleeve / skin shown by FIG. 22 is placed onto the final structure or component, and other methods may be utilized, such as a tape laying machine.

[0102] Page 9 / 16, Fig. 13a shows the internal structures or buttresses and how they overlap as seen on page 9 / 16, and Fig. 13 forms a cross section which can run the entire length of the internal structure or component if the design of the structure or component requires, in this figure the internal base structure is shown to run the entire length of the final structure, or a component with an extended section (lip) is shown in this patent and in 11 / 16, Fig. 14, No. 56, pages 13 / 16, Fig. 16, No. 66, 14 / 16, Fig. 17, No. 70 (also showing the overlap of one set of buttresses in a horizontal position) and 15 / 16, Fig. 18, No. 80, show the vertical buttresses of Fig. 3a and the vertical buttresses of Fig. 3b shown to run two internal buttresses, which are connected at their interface by a suitable mechanism such as glued or bolted (as seen in Nos. 82 and 83).

[0103] In Figure 15c on Page 12 of 16, the male section at isolation does not show a gap within the male section, the male section is shown in Figure 15, No. 63, this gap allows the buttress to traverse both horizontally (62, none) and vertically (58) to the secondary structure or component.

[0104] No. 11 / 16. In Fig. 14, Fig. 58, dashed lines indicate a portion of the horizontal structure as seen in Fig. 3b, Fig. 14 / 16, Fig. 17, Fig. 70. No. 11 / 16, Fig. 14, Fig. 55, Fig. 3b, structure, or component connected to Fig. 14, Fig. 54 section, Fig. 3a.

[0105] It should be noted that Figs. 11 / 16, 14, 12 / 16, 15, 13 / 16, 16 (Fig. 16 shows a telescopic view looking down into the center of the structure and / or component), 17 and 15 / 16, 18 show only two sections of the structure and / or component, although this is applicable to multiple sections such as, but not limited to, large wind turbine blades, where the structure is shown transparent to show the internal structure of the structure or component.

[0106] Page 11 / 16, Figure 14, No. 57 shows the cut that allows a section or buttress as shown in this patent to fit within Figure 3a, Page 14 / 16, Figure 17, No. 74a; Page 11 / 16, Figure 14, No. 52 shows the step connection between two components as also shown in Page 9 / 16, Figure 13, No. 52, and Page 10 / 16, Figure 13b, No. 52, and Page 11 / 16, Figure 14, No. 52; Page 12 / 16, Figure 15 shows a 3D drawing of the completed structure or component.

[0107] Page 12 / 16, Figure 15, number 59 shows the horizontal and vertical buttresses forming the cross section. The overlap of the incoming buttresses from 3a to 3b (or 3b to 3a) is not shown to allow for clarity in Figure 15, but these overlaps where the buttresses in sections 3a and 3b are shown can be seen in Figures 13, 14, 16, 17 and 18 on Page 11 / 16 - Page 15 / 16, Figures 13, 14, 16, 17 and 18, respectively, where Figure 13b is shown. As described in this patent where only one section of the completed structure and / or component is shown, I will use the description of the buttress of section 3b, but depending on the design of the final structure, the buttress of Figure 3b may overlap with the buttress of Figure 3a.

[0108] Page 12 / 16, Fig. 15, No. 64, the edge of the external material (in this case carbon fiber) is not shown in its entirety in order to show the internal structure (horizontal and vertical buttresses).

[0109] Page 12 / 16, Figure 15, No. 62, horizontal buttress, shows both sections 3a and 3b, as previously mentioned, and the overlap is shown on pages 11 / 16-15 / 16. The following Figures 13, 14, 16, 17, and 18 show the connection with the external structure of the completed component or structure, as seen on page 11 / 16, Figure 3a, No. 58b. For illustrative purposes, page 1 / 16, Figure 1 and Figure 2 show the horizontal buttress, No. 5, which can be seen in the completed buttress, No. 70 and No. 72, respectively, on page 5 / 16, Figure 18.

[0110] As shown in Figure 15, Figure 15, Figure 16, Figure 17 and Figure 18, the male section of Figure 3b fits into Figure 3a (female section), Page 12 / 16, Figure 15, No. 63 fits into section Figure 3a (female section).

[0111] Page 12 / 16, Figure 15, number 64 shows the outer sleeve / skin or covering of the final structure and / or component, which is formed by two sections Figure 3a and Figure 3b coming together to form a larger structure as shown in Figure 15.

[0112] Figure 15 on page 12 / 16 shows outer material No. 64, which is flush with the buttress shown in a horizontal position as seen on page 13 / 16, Figure 16, No. 67.

[0113] 15, 15, 60, 3a, 15, 61, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3j, 3k, 3k, 3m, 3m, 3m, 3m, 3m, 3i, 3m, 3m, 3b, 3c, 3d, 3d, 3e, 3f, 3i, 3f, 3b, 3c, 3d, 3e, 3f, 3i, 3f, 3b, 3c, 3d, 3e, 3f, 3b ...

[0114] As shown in pages 3 / 16, 6 / 16, 8 / 16, 9 / 16-15 / 16, including Figures 3, 5, 13, 14, 15, 17, and 18, page 13 / 16, Figure 16, No. 66, the component structures are shown in vertical and horizontal positions, and in page 9 / 16, the internal structure of the buttress is shown separated, as in page 13 / 16, Figure 16, to provide a clearer picture of how the internal structures can overlap with each other's horizontal structures.

[0115] Figure 16 shows the internal structure. The substructures or buttresses shown in Figure 16 (shown in vertical position) can be one, two, three or more depending on the final design and structural requirements of the final structure and / or component. The substructures or buttresses are shown on pages 1 / 16-15 / 16 (page 14 / 16 where only horizontal buttresses are shown). Page 13 / 16, Figure 16, where vertical substructures or buttresses are shown on either side of the horizontal substructures or buttresses. Page 9 / 16, Figure 13, where vertical substructures or buttresses are shown partially by dotted lines, No. 46, No. 47, and No. 48.

[0116] 18, Fig. 18, 81 is the vertical substructure or buttress of Fig. 3a, which overlaps with the vertical substructure of Fig. 3b, No. 75.

[0117] Page 15 / 16, Figure 18 shows one vertical substructure or buttress above a horizontal substructure and lower vertical substructure or buttress, not shown.

[0118] Note that Figure 16, No. 67 shows the surface of the inner base structure buttress in contact with and at the level (flush) with the outer structure of the final structure or component before the final structure or component is covered by the outer material or sleeve / skin, if a sleeve / skin is required.

[0119] It should be noted that on page 13 / 16, Figure 16, No. 68, two sections of a structure and / or component are shown to be placed inside the other between any lengths that are the result of the design of both tool sections, as shown on page 7 / 16, Figures 7 and 8 (although the shape of the tool is shown as a square on page 7 / 16), and the length of penetration into the second component, as shown on page 14 / 16, Figure 17, No. 70 and No. 71, as on pages 11 / 16 to 15 / 16. Please note that pages 11 / 16-15 / 16 (excluding page 13 / 16) are not shown in Figures 14, 56, 58, 15, 59, 62, 63, 16, 66, 69, 17, 70, 72, and 18, 77, 78, 80, and 81 of the structures shown in Figures 12 / 16, 15, and 15b, as well as all other sub- and super-structures, will depend on the final design requirements, as previously mentioned in this patent.

[0120] Page 14 / 16, Figure 17, No. 74a shows the queue.

[0121] Page 14 / 16, Figure 17, No. 70, the lower cutout is No. 52, as shown in Figure 9 / 16.

[0122] Page 14 / 16, Fig. 17, No. 74 shows a section ofPage 14 / 16, Fig. 17, Fig. 3a shows a section of Fig. 3b, No. 70 does not fit within and over it, and horizontal buttress No. 72 fits within the horizontal buttress of No. 70, but can also fit below horizontal No. 70 if required.

[0123] Page 14 / 16, Figure 17 shows how two sections of the structure and / or component (Figures 3a and 3b) fit together, which can also be seen on pages 11 / 16 to 15 / 16. Figures 14, 16 and 18 show that the internal horizontal structures or buttresses on pages 14 / 16, 17, Nos. 70 and 72, show the overlap of these horizontal buttresses (Nos. 70 and 72) and how they join together, as well as the substructures or buttresses which may be in a vertical position as seen in this patent. Page 14 / 16, Fig. 17, No. 71 showing the internal structure of section Fig. 3b of Fig. 17, where the male section fits within the female section of Fig. 3a. Section Fig. 3b shows only a cross-sectional slice of the section of how the two sections of the final structure and / or component fit together; see Fig. 14, No. 12 / 16, Fig. 15 (Fig. 15 does not show the overlap of the buttresses or reverse buttresses of 3a-3b), No. 13 / 16, Fig. 16, No. 14 / 16, Fig. 17, No. 15 / 16, Fig. 18.

[0124] The overlapping parts of Fig. 3b, page 15 / 16 of Fig. 3b, Fig. 18, No. 80 buttress or substructure (shown in vertical position), i.e. the buttress of Fig. 3b, the buttress or substructure of Fig. 18, No. 81 part of Fig. 3a, page 15 / 16 of Fig. 3a, No. 81 part of Fig. 3a.

[0125] Page 15 / 16, Figure 18, number 76 partially shows the depth of penetration of the buttress of section Figure 3a or the vertical buttress of section Figure 3a within part 3b of part 3a.

[0126] 81 shows the overlap depth of buttress No. 75 in Figure 3b.

[0127] Page 15 / 16, Fig. 18, No. 79 shows the cutout to allow the vertical buttress or substructure of Page 15 / 16, Fig. 18, No. 81 in Fig. 3a to move through the buttress (in horizontal position) or substructure as clearly seen in Page 9 / 16, Fig. 3a, No. 51, Fig. 3a, No. 51 does not show any explanation and the lower vertical beam or substructure of Fig. 3a and Fig. 3b as clearly seen in Fig. 18, No. 79, Fig. 17, No. 74a and Page 11 / 16, Fig. 14, No. 57 Section Page is not shown. 15 / 16, Fig. 18, No. 77 shows the overlap and penetration of section 3b of section 3a, non-overlapping 75, and section 80 of section 3a to the buttress or substructure joint (shown in vertical position in this case) of sections 3a and 3b, sections also shown in No. 9 / 16, Fig. 13, No. 48, Page 11 / 16 Fig. 14, No. 56 and No. 58, Page 12 / 16, Fig. 15, No. 59 (overlap not shown), No. 13 / 16, Fig. 16, No. 69 and Page 15 / 16, Fig. 18, No. 80.

[0128] Page 15 / 16, Figure 18 No. 78 shows how section Figure 3a and section Figure 3b fit together, and shows part of the female section that houses the male section (the rest of the internal female section in Figure 18, Figure 3a is not shown). This section is also shown on Page 12 / 16-Page 14 / 16, Figure 15, No. 63, Figure 16, No. 68 and Figure 17, No. 71.

[0129] Page 15 / 16, Fig. 18NO.82, buttress or substructure (shown in vertical position) shows the bolts connecting the buttress or substructure in the sections of Fig. 3a and Fig. 3b The distribution and number of bolts are for illustrative purposes only and will be confirmed in the final design and necessary requirements for structural integrity.

[0130] Page 15 / 16, Figure 18, number 83 shows the buttress or sub-structure (shown in horizontal position) and the bolts, distribution and number of these bolts are for illustrative purposes only and will be confirmed in the final design and necessary requirements for structural integrity.

[0131] Page 15 of 16 of the buttress or substructure in section Figure 3a, Figure 18, Figure 3b, Figure 75 may be executed the entire length of the substructure or buttress buttress shown only as executing a partial length of buttress number 75, Figure 18, Figure 3b, Figure 75 may be executed the entire length of the buttress or substructure buttress or substructure in section Figure 3a, Figure 3b of the two vertical buttresses and vertical buttress section showing how they may overlap along any length buttress length of Figure 3a does not depend on the final design specifications.

[0132] Page 15 of 16. Figure 18, number 84a shows the horizontal buttresses of section Fig. 3b overlapping to any length.

[0133] In Figure 19 on page 16 / 16, 85 shows a loom that produces either 2D or 3D woven materials, or a specialist that winds carbon fiber around a tool and the final structure or component. In the case of 3D materials (in this case, carbon fiber materials), which can be replaced by a carbon fiber tape winder, the woven material is in a mesh shape so that it can follow the shape of the tool, and the two lines showing the woven material loom are for illustrative purposes only and do not form part of this patent.

[0134] Page 16 / 16, Figure 22, No. 86 shows a 2D end view of Page 12 / 16, Figure 15 as an example of the component produced and the final woven fabric when the (woven material) is wrapped around the entire structure or component, and Figure 22, No. 87 shows the direction of movement of the material covering the final structure or component shown in Page 12 / 16, Figure 15 as an example.

[0135] Figure 20 shows the direction of travel of the tool halves, it should be noted that the tool rotation must be synchronized with the rotation and speed of the material release from the loom or tape machine, and in the case of a loom, the loom is producing material as the net shape of the tool.

[0136] Note that it may not be necessary for the tool to rotate, as more sophisticated tape laying machines can rotate around the tool.

[0137] Page 16 / 16, NO 88 shows the central axis of rotation of the material and final structure or component, or each individual tool section (final structure or component shown in Figure 22, individual tool sections shown in Figures 20 and 21), and Figures 20 and 21 show halves of the tool as seen in this patent and in particular Pages 1 / 16, Figures 1 and / or 2, before the tools are combined to form the final structure and / or component, which can be seen on Pages 3 / 16, 6 / 16, 8 / 16 and 9 / 16 to 15 / 16, 13 / 16 (telescopic views, i.e., looking directly down at the structure and / or component).

[0138] The same methods of placing material on the tool or on the final structure or component can be utilized for square or rectangular or other shapes, although other methods can be utilized as desired.

[0139] Page 16 / 16, Fig. 21, number 89 shows the clamps that hold the material in place and provide tension on either side of the tool buttress (the tool buttresses can be seen in Figs. 1-9, also Figs. 1 / 16, Fig. 2, Fig. 6). Note that the diagram showing the tool buttress on page 16 / 16 is not 94 and does not indicate whether it is page 1 / 16.

[0140] 9 or Fig. 2, No. 6 simply shows the buttresses and how the material is arranged around each section of the tool and whether it is one half of the tool or the other half of the tool.

[0141] Page 16 / 16, Figure 19, No. 90 shows the material from the loom and / or tape machine, and No. 91 shows the direction of material movement.

[0142] It should be noted that the loom weaves the material at the same speed as the tool rotates, so the material covers the tool as it rotates, and if the loom is not wide enough to cover the entire length of the tool, care must be taken to ensure tension in the material at all times, and therefore the loom will need to weave in sections along the length of the tool, ensuring that the weave is continuous along the length of the tool and with no breaks between each section.

[0143] However, as previously mentioned, a tape laying material may be utilized to place carbon fiber tape (carbon fiber is the preferred material), and if this is the case, the tool may not need to rotate.

[0144] Page 16 / 16, No. 93 shows the flange in 3D as shown in this patent and does not show the flange that accommodates the incoming buttress from the incoming tool section as shown in Page 1 / 16, Page2 / 16, Page4 / 16, Page5 / 16, Page7 / 16no14 / 14h and No. 15, as well as Page12 / 16, Figure 15a.

[0145] The present invention solves and overcomes the problems associated with mass production of large structures through expert tool design, which can be used to manufacture components for structures such as, but not limited to, large wind turbine blades. Currently, these types of structures are manufactured in one long section and are produced for the most part by hand processes with limited precision, as long as the exact material is laid down, which can result in possible localized stress points that can result in catastrophic failure of the final component. This form of production, produced for the most part by hand processes, does not leave room for any degree of automation, and as such, the number of large structures that can be produced on one site is very limited. The present invention is a basic tool for manufacturing final structures and / or components that rely on structures and / or components made from composite materials such as carbon fiber composites, carbon fiber, the preferred material of this patent.

[0146] The present invention through specialized tooling designs allows these large components / structures to be manufactured in or near one shot process, which means that after the tool is covered with the desired material, the two sections of the tool can be combined to form the component, as shown, and the combination of the tool sections can also be done by a suitable mechanism that is not part of this patent, which also can be fully automated. Thus, the entire process can be fully automated, thus overcoming many inaccuracies associated with hand processes with the added advantages of lower cost of production, shorter production time and larger production volumes, resulting in a lower final selling price and ultimately leading to lower cost of electricity to the consumer (take turbine blades as an example). The tooling designs as shown in the claims can also be utilized for other large structures such as aircraft fuselages, front cones, bodies etc., as well as other large structures like housings, hotels, hospitals, bridges, but not limited to these. The tooling innovative designs allow components to be assembled in sections (if desired) and connected together in innovative ways, as described in this patent application.

[0147] Overcoming many of the problems associated with transporting large structures and / or components and placing them offshore in situ with reference to the wind turbine blades (if they are to be located offshore) eliminates the need for specialist offshore vessels to be utilized to place the turbine blades onto the generator mechanisms and the major costs associated with this process.

[0148] The tooling design also shows how large structures such as enclosures, hospitals, warehouses etc can be quickly constructed and shipped anywhere in the world, in case of disaster areas they can be constructed and shipped in time, the tooling can be pre-fabricated, the tooling can be fabricated and maintained for scenarios such as these and can also be utilized to build very low cost enclosures whenever the need is required, overcoming the problem of shortages in the U, where there is a fundamental and growing requirement for rapid low cost housing structures can be constructed and K-typed in a day like a large production line and then transported or shipped by road or air, if the height of the completed structures is too large for transport by road or rail or air they can be produced near deep water port docks and placed directly on container ships.

[0149] In addition to forming large structures as seen in this patent, the designs in this patent can also be used to create molds as described in this patent, and in some variations, huge structures such as caissons can be quickly manufactured, and cheaper than current manufacturing methods which are time consuming and costly to produce due to the steel structural components of these structures, which take a great deal of time to build these structures, and at that time, the remaining frames / surfaces that sit on the foundations formed by the caissons cannot be built as the structure is not in place, and this has the effect of preventing the construction of further structures such as warehouses or airports, or indeed seawater ports on reclaimed land in most cases when reclaimed from sea.

[0150] Draw a conclusion The above description of innovative mechanisms and systems is intended to provide a method for constructing large structures and, if necessary, joining these large structures together to form large wind turbine blades or aircraft Joining these larger structures to form even larger structures, such as the fuselage of a train, or indeed the front nose of a train and the body of a living organism, Minimize the need to create larger structures such as stock and fabricable working structures such as enclosures, warehouses, hospitals, and skyscrapers. Examples include, but are not limited to:

[0151] When joining large structures or components by sections, difficulties can arise in the structural integrity of the components at these joints, and local stress points can occur at the joints of these large structures or components (although the references to large structures or components refer to the principles shown in this patent, which also apply to smaller structures or components). This is because the substructure design in this patent allows the entire length of a component, such as a large wind turbine blade, to be carried internally, thus eliminating local stress points. When necessary (or as a single horizontal substructure), there is a large internal "superstructure" designed as a cross section formed by the substructures, such that when the sections are joined (connected), there are no local stress points. The overlap of each of the vertical and horizontal substructures that form the internal structure, as shown in this patent, eliminates such local stress points.

[0152] The substructure or superstructure may be long or short in length as required by the structural design, and as noted above, this structure may also be used to minimize any localized "stress points," thus the outer sleeve / skin or cover need not be a structural part of the entire component structure, but may simply function as an outer skin.

[0153] As described in this patent, the components are supported by an internal cross-sectional substructure, and in addition, this internal substructure is further structurally supported by the fact that one section may be placed inside the other section forming an internal structure that spans both parts of the tool. The amount of movement in length of the female section by the male section of the two structures depends on the ultimate structural integrity requirements of the structure or component, and therefore the structure and / or component tool design takes this into consideration.

[0154] As described in this patent, there may be a requirement that the final structure or component have no horizontal structures and / or buttresses, or no buttresses or one vertical substructure or buttress below it, depending on the final construction and design requirements of the completed structure or component.

[0155] The current method, particularly in wind turbine blades, is to produce these structures as one large section.

[0156] However, there are many problems that arise with the production of these large structures, and these problems are well documented. To this end, I will name a few, but the significant amount of man-hours required to manufacture these structures, for example, structures such as wind turbine blades, where most processes are very intensive, require a significant amount of time, resulting in substantial manufacturing costs, making automated or semi-automated processes non-cost-effective. In addition to the above, the process of hand laying up materials to form composite structures can involve inaccuracies in material deposition, resulting in localized stress points that can lead to structural failure of the component, making them difficult to manufacture. Furthermore, internal superstructures must be placed within the blade as a secondary process, which adds to the cost of blade manufacture and again adds to the possibility of these structures failing due to the fact that these structures are secondary processes; if an internal structural component fails, the entire component will fail.

[0157] The above are some of the many challenges that must be overcome in designing and manufacturing large structures at competitive costs in order to achieve market penetration and reduce final selling prices.

[0158] In the case of wind turbine blades (for example, taking these structures), which may be over 100m long, there is also the substantial additional cost of transporting these large structures so that they can be deployed in situ, with only a few ocean-going vessels having the technology and capability to undertake such a task, again increasing the cost of the total blade.

[0159] Although a lot of time, research and investment has been put into developing the production of these large structures and the expertise of the companies involved, it is understood that the process is still based on a largely non-automated system of production and therefore the cost and time, and indeed the structural integrity of the components, can result in very large structures that are not economically viable in the medium term and long term future.

[0160] I believes that I overcome many of the above problems by creating sections or large structures with an internal superstructure and an external structure, where there are no secondary processes apart from joining the two halves of the tool, and this can be done in a fully automated process by utilizing an external mechanism to combine the two halves of the tool. To produce the part, the composite material needs to be wrapped around the tool halves before combining them, as shown in this patent, and again, this can be done in a semi-automated or fully automated process, and there are several technologies currently commercially available that can perform this process. I mention my preferred technology in this patent, but I am not limited to this technology, and therefore, when it is necessary to combine two halves of the tool to form the final structure or component, other viable technologies that are available in the market can be utilized.

[0161] Additionally, all material thicknesses and material structures can be designed to fit the structural requirements of the component and placed in place by an automated process such as that shown in this patent, eliminating the issues associated with hand-laying materials to manufacture said structure or component, thereby eliminating the issues of inaccuracy in the deposition of composite structure or component materials. Another major cost savings is that by producing these components in 25 meter long plus sections (below), it facilitates transportation and provides major cost savings associated with placing these blades (if the final component is a blade for onshore wind).

[0162] This form of structure can be extremely robust for joining together two or more sections of large structures such as wind turbine blades, aircraft fuselages, train nose cones, etc., but is not limited to cases where the internal structure can act as a superstructure for any of the above structures, plus be manufactured in one step.

[0163] This process allows structures with high inherent strength to be produced more efficiently and at a lower cost than known methods. This is particularly advantageous in situations where structures must be constructed quickly, such as in the event of a natural disaster (e.g., earthquake, storage, flooding, etc.), military scenarios, or as a further example, where medical buildings are required at short notice.

[0164] The methods and embodiments described herein are not limited to the implementations described above. Modifications and additions can be made to the tools and methodologies to enhance their particular usability, for example, by adding additional equipment and steps. In particular, the present invention and its embodiments are configured such that they can be usefully expanded or enhanced using state-of-the-art technology by weaving and utilizing materials using advanced 3D weaving technology currently available, where 3D weaving technology can combine various materials to provide optimal structural integrity at minimal costs associated with material design.

Claims

1. 10. A tooling design according to claim 1, which allows large or small structures or components to be manufactured in a possible one-stop automated process, wherein secondary processes are completely limited or reduced to a minimum, and automated processes can be utilized to reduce inaccuracies associated with manual production, thereby reducing the cost and time of said manufacturing, wherein the tooling structure formed by the two halves of the tool is to be covered (by a suitable methodology) with a suitable material such as carbon fiber, such as a 3D carbon fiber fabric, other methods can be deployed to cover the tool with the necessary material as needed to form the final required structure and internal base structure, wherein horizontal buttresses overlap with the horizontal buttresses of the incoming opposing tool, and the vertical buttresses of each tool enter the flange of the corresponding tool, with the length within the final structure or component depending purely on the structural requirements of the final structure and / or component, and the width ) is an inner diameter of the outer diameter of the tooling (but need only be an inner diameter), this superstructure is designed to allow the necessary strength and can be designed into a final structure or component such that these internal structures or superstructures can be interconnected with secondary finished structures or parts, such that multiple completed structures can be connected together as needed to form larger structures such as wind turbine blades or aircraft fuselages or housings, and so that these internal structures or superstructures can be interconnected with secondary finished structures or parts, for example, but not limited to, to form caisson structures (as forms for concrete), building structures, train and aircraft structures and components, automotive parts and automotive body structures, once the tooling is properly removed the tooling can be removed. It should be noted that the final structure formed by the tooling will form the mould that will form the caisson, but in some final structures or components the final structure or component design may require this to be the case and may require structural integrity or otherwise have no vertical buttresses or indeed no vertical buttresses, but in some final structures or components there may only be a need for one or more vertical buttresses or vertical buttresses.

2. As claimed in claim 1, the vertical buttresses of each tool section are offset relative to one another to allow the two internal vertical buttresses to come together by entering the flanges of the respective tool sections, thus forming the final tool.

3. As claimed in claim 1, the final structure or component produced by the two independent tools is joined together by suitable means to form the final structure and / or component once the material has hardened (where the material is the preferred material of this patent, but is not limited to, a material that forms one structure and / or component).

4. As defined in claim 1, vertical buttresses (by this I I mean vertical buttresses above or below horizontal buttresses) of a completed structure or component, whether vertical or horizontal, allow for internal structural vertical and / or horizontal buttresses of each completed structure or component when attached to another completed structure or component, and therefore the buttresses of these structures or components allow for these internal buttresses (of two or more structures or components) to interconnect, thus allowing for seamless joining of such secondary or multiple structures and / or components with appropriate connections such as bolts or bonds.

5. As claimed in claim 1, the internal horizontal buttresses and vertical internal buttresses of one completed structure or component for interconnection with a second completed structure or component can form a strong bond in which the internal horizontal buttresses and internal vertical buttresses can overlap and run the entire length of the two internal structures of the two independent structures and / or components, and this internal structure formed by the cross sections of the horizontal and vertical buttresses is an internal structure that becomes an integral structural part of both structures or components so joined.

6. As stated in claim 1, the patent also shows how the completed structure, with minor modifications, can be used as a mold for larger structures as described, except for the fact that the mold remains acting in situ as an integral part of the structure contributing to the structural strength and integrity of the structure made by the mold, thus making large structures quicker and less expensive.

7. As claimed in claim 1, each horizontal buttress of each tool forms an airtight fit when the two halves of the tool are joined together such that when the tool sections are joined together, the material is compressed between the respective horizontal buttress of each tool, forming a final structure or component upon tool removal, each horizontal buttress.

8. As claimed in claim 1, the internal structures or buttresses are covered with material, as are all surfaces of each individual tool (apart from those areas where the individual tool should not be covered), and this material covering the buttresses forms the internal structures of the final structure and / or component, and these internal structures of the final structure or component are formed by removal of the tools once the material has hardened, and if the material requires hardening, the material hardens.

9. As claimed in claim 1, the combination of the two tooling structures when joined also forms a horizontal internal buttress structure in which the material forming this internal structure is twice the thickness of the material covering the vertical buttresses of the structure or component.

10. As set forth in claim 1, one of the flanges that is part of the horizontal buttress in each tool is designed to move in a parallel direction towards the other flange in that tool section to compress the material covering the vertical buttress that intervenes between the flanges to form the final structure or component produced by the tool.

11. As stated in claim 1, if the final structure produced by the tooling is, for example, that of an aircraft fuselage, there is a requirement for a horizontal buttress forming the floor pan of the aircraft, and not just one interior lower "vertical buttress and an upper" vertical buttress on the surface opposite the horizontal buttress, which lower vertical buttress can be cut as needed to accommodate the interior requirements of the aircraft (without losing structural integrity), such as, but not limited to, electronics, undercarriage, cargo, etc.

12. As stated in claim 1, the internal horizontal buttress structure of one completed structure or component can be interconnected with a second completed structure or component, and the second completed structure or component can be joined to the two horizontal structures together, with their corresponding surfaces forming an airtight fit that allows for a strong joining of these surfaces which can run the length of the two internal structures if required, meaning that the two structures or components can be joined together seamlessly by suitable connections such as bolts or joints.

13. As stated in claim 1, the internal vertical buttress structure of one completed structure or component can be interconnected with a second completed structure or component, whose corresponding surfaces form an airtight fit allowing for a strong joining of these surfaces which can run the length of the two internal structures if required, and also means that the two vertical buttress structures of each structure or component can also be joined together, thus allowing for seamless joining of the two structures or components by appropriate connections such as bolts or bonds.

14. To allow the vertical and horizontal buttress structures to overlap with a secondary completed structure or component, respectively, as described in claim 1, the tool is designed such that the final structure or component formed by the tool accommodates extensions or lips of both the horizontal and vertical buttresses to allow for the creation of an overlap of the vertical and horizontal structures in the final structure or component.

15. As claimed in claim 1, there can be multiple vertical internal buttresses designed into the tool.

16. As claimed in claim 1, there may be only one horizontal buttress designed into the tool, but other horizontal buttresses can be incorporated into the finished structure or component via partitions.

17. A tool as claimed in claim 1, characterised in that each of the two halves of the tool, when brought together by suitable means, forms an overall tool which, when the tool is removed, forms the final structure or component.

18. 10. The method of claim 1, wherein the tool design includes forming a male portion such that one structure and / or component can fit within a secondary structure or component forming a re-formed fit between the two structures or components, and the length or distance that one "male" section of the structure or component penetrates and traverses the "female" section of the other structure or component depends on the length of the male section and the required structural integrity of the joint.

19. As claimed in claim 1, the joint between two or more finished structures or components is a smooth, perfect fit, such that the outer material or sleeve / skin, if there is a requirement for an outer sleeve / skin, flows seamlessly from one structure or component to the other.

20. As claimed in claim 1, the final structure or component may incorporate carbon fiber composite poles or suitable materials to act as reinforcement for the concrete structure formed by the mould, such caissons may act as reinforcement for the concrete structure, including but not limited to these.

21. As described in claim 1, the structure of the mold may have, but is not limited to, a fabric that can be placed around the mold neck so that when the mold is released from the shore and concrete is poured into the mold in situ, the concrete does not spill onto the sea or other water surface.

22. As claimed in claim 20, the structure or component may act as a mould for a larger structure such as a caisson, where (for example) carbon fibre poles / rods may be placed within the mould to form grid sections which may act as structural reinforcement for the (e.g. concrete) material.

23. As stated in claim 5, the internal cross section formed by both the horizontal buttress and the vertical buttress, known as the superstructure (assuming there are two vertical buttresses, there may be a requirement for only one vertical buttress due to design requirements, or both, the requirement for only one vertical buttress may run the entire length of the internal final structure and / or component, and may extend beyond the boundaries of the main structure and component if the design of the final structure or component requires it).

24. As claimed in claim 16, the partitions are placed within the final structure or component to increase the number of horizontal buttresses to the full depth of said structure or component intersecting both vertical and horizontal buttresses, allowing material to be poured into the finished structure (in this case concrete, but not limited to), thus the partitions form a 3D grid honeycomb system, thus producing a substantial number, number and dimensions of concrete depending on the size of the final mould and the structural requirements of the final large structure.

25. As stated in claim 24, the partitions can be placed within final structures or components, in which case if they are large structures such as houses, warehouses, hospitals and any other such large structures, the partitions can be utilized to form rooms or separate small or large spaces necessary for human habitation or can be used in other ways.

26. As claimed in claim 13, a plurality of structures or components may form a larger structure such as, but not limited to, a wind turbine blade, an aircraft fuselage, a ship hull, etc. In the case of architectural structures, the structures or components may be joined both vertically and / or horizontally.

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