Method for manufacturing a structure and method for manufacturing a plurality of structures

Abstract

To provide a manufacturing method of a structure which can simply manufacture a structure which is constituted of an outer skin member and an inner wall member at its inner face while restricting an outer shape of a structure to a predetermined size.SOLUTION: A manufacturing method of a structure includes: a step of feeding gas into an inside of a skin member 10 forming an outer shape of a structure 1 to inflate the skin member; and sticking an inner wall member 11 to an inner face of the outer skin member as an inner wall while restricting inflation of a part of the outer skin member in an inflated state from an outside.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a structure, and a method for manufacturing a plurality of structures, which inflate an outer skin member from the inside and regulate a part of the swelling from the outside to attach an inner wall member to the inner surface of the outer skin member to form an inner wall of the structure.

Background Art

[0002] Structures having an internal space are widely used in fields such as tents and temporary houses. Such structures are required to have a certain strength that can withstand use outdoors and indoors. Various studies have been conducted on imparting strength to structures. For example, Patent Document 1 discloses a structure including a thin film body and a foaming material.

[0003] The structure described in Patent Document 1 is a structure having a closed space inside, and is composed of a thin film body arranged on the outside and a sprayed foaming material fixed to the inner surface thereof. The thin film body is joined to a base arranged on the ground, and can be inflated and made self-supporting by blowing air into the inside of the thin film body by a blower. An operator enters the inside of the structure while maintaining the shape of the self-supporting thin film body, brings a foaming device into the inside thereof, and sprays a foaming material on the inner surface of the thin film body to produce an inner wall of the structure.

[0004] The structure described in Patent Document 1 can be easily manufactured, and can ensure strength and maintain a stable form without using structures such as wooden or steel columns and beams. In addition, since it is composed of an inner wall made of a foaming material, it has heat insulation and sound insulation properties and can be used as a living space. Therefore, it can be utilized as a temporary house or a warehouse in the event of a disaster when a living environment is required quickly.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] However, in the conventional method for manufacturing a structure, air is blown into the inside of a thin film body to form the external shape of the structure. Therefore, as shown in FIG. 7, the thin film body bulges outward like a balloon, and it is difficult to manufacture with the external shape being uniformly aligned. Further, due to the non-uniform external shape after completion, difficulties arise when loading onto a vehicle during transportation, or when a large number of structures have to be arranged within a limited site, the installation space may not be fully utilized.

[0007] In addition, when such a structure is utilized as a temporary housing or the like during a disaster, it may be necessary to manufacture a large number of structures in a short time. However, in the conventional manufacturing method, the structures have to be manufactured one by one, and there is room for improvement in terms of speed.

[0008] Therefore, the present invention has been made in view of the above matters, and provides a method for manufacturing a structure, and a method for manufacturing a plurality of structures, which can manufacture the external shape of a structure composed of an outer skin member and an inner wall member on its inner surface, while regulating the external shape to a predetermined size and manufacturing a plurality of structures simultaneously.

Means for Solving the Problems

[0009] This invention has been made to achieve the above problems, and is characterized by the following.

[0010] The method for manufacturing a structure according to the present invention includes a step of feeding a gas into the inside of an outer skin member that forms the outer shape of the structure to expand the outer skin member, and a step of attaching an inner wall member to the inner surface of the outer skin member to form an inner wall while regulating the bulge of a part of the expanded outer skin member from the outside. See, the restriction from the outside forms at least one wall of the structure, and the wall is perpendicular to the ground. It is characterized by this.

[0011] In the method for manufacturing a structure according to the present invention, it is preferable that the regulation from the outside is performed by a bag body into which gas is introduced inside and which contacts the inflated outer skin member.

[0012] In the method for manufacturing a structure according to the present invention, it is preferable that the bag body is an outer skin member different from the outer skin member.

[0013] In the method for manufacturing a structure according to the present invention, it is preferable to include a step of forming a communication portion that communicates the outer skin member and the bag body.

[0014] In the method for manufacturing a structure according to the present invention, after the step of using the inner wall member as the inner wall, it is preferable to include a step of separating the communication portion.

[0015] In the method for manufacturing a structure according to the present invention, it is preferable to include a step of forming a window of the structure at the separation location of the communication portion.

[0016] In the method for manufacturing a structure according to the present invention, due to the regulation from the outside, the structure Sky preferably forms a well.

[0017] In the method for manufacturing a structure according to the present invention, due to the regulation from the outside, it is preferable to form opposing side surfaces of the structure.

[0018] The method for manufacturing a plurality of structures according to the present invention includes arranging side by side outer skin members that form the outer shapes of the plurality of structures, introducing gas inside each of the outer skin members, and inflating them; and attaching an inner wall member to the inner surfaces of the regulated plurality of outer skin members to form an inner wall while regulating the swelling of a part of the outer skin member by another outer skin member adjacent to the outer skin member. The Adjacent other outer skin members regulation from the forms at least one wall of the plurality of structures, and the wall is perpendicular to the ground.

[0019] In the method for manufacturing a plurality of structures according to the present invention, it is preferable that the outer skin member and at least one of the other adjacent outer skin members communicate with each other at a communication portion.

[0020] In the method for manufacturing a plurality of structures according to the present invention, it is preferable to include a step of separating the communication portion after the step of forming an inner wall with the inner wall member.

[0021] In the method for manufacturing a plurality of structures according to the present invention, it is preferable to include a step of forming a window of the plurality of structures at a separation location of the communication portion.

[0022] In the method for manufacturing a plurality of structures according to the present invention, due to the restriction from the other adjacent outer skin member, the plurality of structures Sky Preferably form a well.

[0023] In the method for manufacturing a plurality of structures according to the present invention, due to the restriction from the other adjacent outer skin member, it is preferable to form opposing side surfaces of the plurality of structures.

[0024] The above summary of the invention does not list all the features necessary for the present invention, and sub - combinations of these feature groups can also be inventions.

Effects of the Invention

[0025] According to the present invention, a wall perpendicular to the ground can be fabricated by the outer skin member and the inner wall member attached to its inner surface, and structures composed of these vertical walls can be fabricated according to a predetermined size. Further, a plurality of such structures can be fabricated simultaneously.

Brief Description of the Drawings

[0026]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Mode for Carrying Out the Invention

[0027] Hereinafter, preferred embodiments for carrying out the present invention will be described with reference to the drawings. It should be noted that the following embodiments do not limit the invention according to each claim, and not all combinations of the features described in the embodiments are essential for the solution means of the invention.

[0028] FIG. 1 is a perspective view of the structure according to the present embodiment, FIG. 2 is a cross-sectional view taken along line A-A of FIG. 1, FIG. 3 is a partial enlarged view B of FIG. 2, FIG. 4 is a perspective view showing the outer shape regulation method according to the first embodiment, FIG. 5 is a cross-sectional view showing the outer shape regulation method according to the second embodiment, FIG. 6 is a cross-sectional view showing the outer shape regulation method according to the third embodiment, and FIG. 7 is a cross-sectional view of the structure according to the conventional embodiment.

[0029] As shown in FIGS. 1 and 2, the structure 1 according to the present embodiment is composed of a wall surface and a ceiling in which the inner wall member 11 is fixed to the inner surface of the outer skin member 10, and has a space inside where people can enter and exit.

[0030] The outer skin member 10 is arranged outside the structure 1 as shown in FIG. 1 when the structure 1 is completed, and forms the overall outer appearance shape. The sprayed inner wall member 11 is fixed to the inner surface of the outer skin member 10, and the outer skin member 10 and the inner wall member 11 are integrated to form the wall surface of the structure 1.

[0031] Before the structure 1 is manufactured, the outer skin member 10 is a substantially bag-shaped thin film body. As shown in the manufacturing method of the structure 1 described later, air flows into the substantially bag-shaped interior by a blower 60, and the interior pressure is increased to inflate it. Thereafter, by adhering and curing the inner wall member 11 to the inner surface of the outer skin member 10, the inner wall member 11 adheres to the inner surface of the outer skin member 10. Therefore, for the outer skin member 10, a material that does not break with respect to the tensile force generated in the plane due to the air pressure applied inside by the blower 60 is used. Examples of the material of the outer skin member 10 include a resin base material (which may be a resin film or a resin sheet), a paper base material, a leather base material, etc. Note that the material of the outer skin member 10 may be other than these. Examples of the resin base material include acrylic, polyolefin, polyester, nylon, polyethylene, and polyvinyl chloride, etc. Examples of polyolefin include polypropylene, etc. Examples of polyester include polyethylene terephthalate, etc. As an example of the resin base material, it contains an ultraviolet absorber. Examples of the paper base material include high-quality paper, Japanese paper, Western paper, synthetic paper, non-woven fabric, etc. The outer skin member 10 may contain one kind of material or two or more kinds of materials. When the structure 1 is installed outdoors, it is preferable that the outer skin member 10 has water resistance, water repellency, or ultraviolet resistance.

[0032] As the inner wall member 11, a foamed material is preferably used. Examples of the material of the foamed material include acrylic, polyurethane, polystyrene, phenol, polyvinyl chloride, polyolefin, urea resin, urethane-urea resin, silicone, polyimide, melamine, glass, ceramics, soil, explosive food materials, etc. Hereinafter, the case where the inner wall member 11 is a foamed material will be mainly described, but as the inner wall member 11, a non-foamed material may be used.

[0033] As the foaming material, a conventionally known foaming material that foams and cures after being sprayed in a mist form can be appropriately selected and used. Since innumerable air bubbles are formed in the foaming material after curing, making it a material containing a large amount of air, it becomes a lightweight material with excellent heat insulation and sound insulation properties. The thickness of the foaming material at the completion of the structure 1 may be such that it can be self-supporting and function as a wall surface constituting the living space when it is made into a wall surface integral with the outer skin member 10, and it may be appropriately set according to the required heat insulation and sound insulation properties. Also, the thickness of the foaming material does not have to be constant. For example, the lower part may be thicker and the upper part may be thinner.

[0034] As shown in FIG. 1, the structure 1 is composed of a front surface 20, left and right side surfaces 30, a back surface 40, and a ceiling 50, using the outer skin member 10 and the inner wall member 11 integrated as described above. Also, the structure 1 forms a space closed by these elements and the ground. In the present embodiment, a structure without a bottom surface in contact with the ground will be described, but the components of the structure 1 are not limited to this, and it may have a bottom surface and form a closed space together with the front surface 20, left and right side surfaces 30, back surface 40, and ceiling 50. Also, in the present embodiment, the front surface 20, left and right side surfaces 30, back surface 40, and ceiling 50 will be described with a structure in which they are connected seamlessly by a single substantially bag-shaped outer skin member 10, but the shape of the outer skin member 10 is not limited to this, and it may be manufactured by being divided into each of the front surface 20, left and right side surfaces 30, back surface 40, and ceiling 50, and the respective elements may be joined using known means such as welding, tape, or an adhesive.

[0035] As shown in FIG. 1, an access hole 21 of a size that allows a person to enter and exit is provided in the front surface 20. A door and a frame (not shown) are attached to the access hole 21, and an openable and closable entrance is installed. Note that the structure of the entrance is not limited to this, and for example, a simple blind such as installing a curtain-like sheet above the access hole 21 and fixing the edge of the access hole 21 and the curtain-like sheet with a hook-and-loop fastener may be used.

[0036] On the back surface 40, as shown in FIG. 2, an air inlet hole 41 into which the duct of the blower 60 can be inserted is provided. The air inlet hole 41 is provided, for example, in the outer skin member 10 corresponding to the back surface 40, and is a through hole or the like that is slightly larger than the outer diameter of the duct of the blower 60. The air inlet hole 41 can be closed by a lid-like component or the like (not shown) when the duct of the blower 60 is not inserted. In the present embodiment, the structure in which the air inlet hole 41 is provided in the back surface 40 will be described, but the position of the air inlet hole 41 is not limited to this, and it may be located on either the front surface 20 or the left and right side surfaces 30.

[0037] At the lower parts of the front surface 20, the left and right side surfaces 30, and the back surface 40 that are in contact with the ground, as shown in FIG. 3, a plurality of dowels 12 are provided at appropriate intervals over the entire circumference of the edge in contact with the ground of the structure 1. When fixing the structure 1 to the ground, since a peg 71 as shown in FIG. 3 is passed through the dowel 12 for use, it is preferable that the inner diameter of the dowel 12 is formed slightly larger than the thickness of the peg 71.

[0038] Next, a manufacturing method of the structure 1 having the above characteristics will be described.

[0039] [First Embodiment] First, the outer skin member 10 is installed with the substantially bag-shaped opening facing downward so as to close the opening on the ground. Next, as shown in FIG. 3, the peg 71 is passed through the dowel 12, the peg 71 is driven into the ground, and the peripheral edge of the opening of the outer skin member 10 is fixed to the ground. Since air will flow into the internal space closed by the outer skin member 10 and the ground by the blower 60 as described later, the outer skin member 10 is fixed with a strength that prevents it from moving due to the pressure in the internal space of the outer skin member 10 caused by the inflow of air. By using such a method of fixing the structure 1 with the peg 71, even when moving the completed structure 1, it is only necessary to remove the peg 71, and it can be easily moved. Since the structure 1 is lightweight, it may be fixed with the peg 71 even during use so as not to move due to external forces such as wind, and fixing means for reinforcement may be added as necessary.

[0040] Next, using an outer shape regulating jig 80 as shown in FIG. 4, the outer shape of the structure 1 is regulated from the outside. The outer shape regulating jig 80 regulates the left and right side surfaces 30 of the structure 1 to be perpendicular to the ground and have a constant width, and has a wall surface made of, for example, wood. Note that the outer shape regulating jig 80 not only regulates the width of the left and right side surfaces 30, but may also use a jig such as a frame body surrounding the four sides of the structure 1.

[0041] Next, air is pressurized and caused to flow into the inside of the outer skin member 10 using the blower 60. Due to the inflow of air, the internal space is pressurized, and the outer skin member 10 bulges outward to the size regulated by the outer shape regulating jig 80. Since the peripheral edge of the outer skin member 10 is fixed to the ground, the outer skin member 10 can be made self-supporting by the pressurization by the blower 60. At this time, the access hole 21 is closed by any closing means. The air sent into the inside of the outer skin member 10 is performed by inserting a duct extending from the blower 60 into the air inlet hole 41, but it may also be allowed to flow in from a slightly opened gap or the like of the access hole 21. Further, if a gap is generated between the peripheral edge of the outer skin member 10 and the ground and the internal air leaks, a sandbag or the like may be used to block the gap. Note that the blower 60 is required to have a performance capable of making the outer skin member 10 self-supporting and generating a tensile force in the plane of the outer skin member 10. For example, it is preferable to use a high-output blower equipped with a pressure type turbo fan or a sirocco fan.

[0042] Next, with the outer skin member 10 standing independently, while continuing the inflow of air by the blower 60, the access hole 21 is opened, and the operator enters the space of the outer skin member 10 together with the foaming device for injecting the foaming material. After the operator enters, the access hole 21 is closed again to maintain the swelling of the outer skin member 10 to the outside. Then, the operator manually sprays the foaming material in a mist form onto the inner surface of the outer skin member 10. The sprayed foaming material adheres to the inner surface of the outer skin member 10 and expands as it foams. The foaming material that has completed foaming adheres to the outer skin member 10 and hardens, so that the outer skin member 10 and the foaming material become integrated. If the hardening of the foaming material is completed and the structure 1 can stand independently without pressurizing the internal space, the blowing from the blower 60 can be stopped. Note that the method of attaching the inner wall member 11 to the outer skin member 10 is not limited to the above, and conventionally known coating means can be appropriately selected and used.

[0043] In this way, the outer skin member 10 swells outward due to the internal pressurization by the blower 60, and with a tensile force generated in the plane of the outer skin member 10, the foaming material is sprayed and fixed to the inner surface of the outer skin member 10. Therefore, even if the pressurization from the blower 60 is removed, a tensile force remains in the outer skin member 10, while a compressive force is generated in the hardened foaming material. Accordingly, in the structure 1, the outer skin member 10 arranged on the outside bears the tensile force, and the foaming material arranged on the inside bears the compressive force to become integrated, so that the form becomes stable.

[0044] By using such an outer shape regulating jig 80, even when the internal space of the outer skin member 10 is pressurized, the outer skin member 10 does not swell beyond the width set by the outer shape regulating jig 80, is perpendicular to the ground, and the opposing wall surfaces can be formed at a constant interval.

[0045] [Second Embodiment] The method for regulating the outer shape according to the first embodiment described above has been described for the case where the outer shape is regulated by the outer shape regulating jig 80. Next, the method for regulating the outer shape according to the second embodiment to be described is a method for regulating the outer shape having a form different from that of the first embodiment. For members that are the same as or similar to those in the first embodiment described above, the same reference numerals are given and the description thereof is omitted.

[0046] The method for regulating the outer shape according to the second embodiment shown in FIG. 5 is a method for regulating the outer shape by adjacently arranging a plurality of structures 1 without using a jig for regulating the shape of the wall surface as in the first embodiment. As shown in FIG. 5, on the side surfaces where the structures 1 are in contact with each other, one structure 1 regulates the outer shape of the other structure 1, and similarly, the other structure 1 regulates the outer shape of one structure 1. For blowing air into the outer skin member 10, one blower 60 is used for each outer skin member 10. If the pressures in the internal spaces of the adjacent structures 1 are the same, the left and right side surfaces 30 in contact with each other are kept perpendicular to the ground.

[0047] By using such a method for regulating the outer shape, it is possible to form opposing wall surfaces at an arbitrary interval and perpendicular to the ground without using materials other than the members constituting the structure 1 and without using a jig.

[0048] [Third Embodiment] The method for regulating the outer shape according to the second embodiment described above has been described for the case where the outer shape is regulated by adjacently arranging a plurality of independent structures 1. Next, the method for regulating the outer shape according to the third embodiment to be described is a method for regulating the outer shape having a form different from that of the second embodiment. For members that are the same as or similar to those in the first and second embodiments described above, the same reference numerals are given and the description thereof is omitted.

[0049] The outer shape regulation method according to the third embodiment shown in FIG. 6 is a method in which the adjacent structures 1 are connected by the communication part 31 and the internal spaces are connected, and in this state, as in the second embodiment, one structure 1 regulates the outer shape of the other structure 1. As shown in FIG. 6, the air that has flowed into the outer skin member 10 from one blower 60 passes through the communication part 31 and flows into the adjacent outer skin member 10. The air that has flowed in from the communication part 31 can inflate and self-stand a plurality of adjacent outer skin members 10. In the present embodiment, as shown in FIG. 6, a method of inflating a plurality of outer skin members 10 using one blower 60 will be described. However, the number of blowers 60 is not limited to one, and a number of blowers 60 less than the number of outer skin members 10 may be used.

[0050] By using such an outer shape regulation method, it is possible to form a wall surface perpendicular to the ground without using materials other than the members constituting the structure 1, such as jigs, and with a smaller number of blowers 60 than the structure 1.

[0051] On the inner surfaces of the plurality of outer skin members 10 that are communicated by the communication part 31 and are in a self-standing state, the foaming material is sprayed as described above and adheres to the outer skin member 10 to become integrated. At this time, the adjacent structures 1 are in a state of being connected and hardened by the foaming material sprayed on the periphery of the communication part 31. However, after the foaming material has hardened, the structures 1 can be made independent by separating the communication part 31. Through holes are formed in the separated structures 1 at the positions where the communication part 31 was located, and these can be utilized as windows when the structures 1 are used as living spaces or the like.

[0052] According to the method of manufacturing the structure 1 implemented as in the above-described third embodiment, a plurality of structures 1 can be manufactured simultaneously using a small number of blowers 60 without using jigs or the like other than the components of the structure 1. Further, since the structure 1 to be manufactured is composed of the outer skin member 10 and the foam material on its inner surface, it is lightweight and the outer shape can be made uniform. Further, when the structure 1 is used as a living space, since through holes that can be used as windows are formed in advance, the working time can be shortened.

[0053] The structure 1 can be used for temporary housing in disaster-stricken areas or developing countries. In such cases, generally, a plurality of structures 1 are often required. On the other hand, it is assumed that it is difficult to obtain sufficient members for manufacturing jigs such as the outer shape regulation jig 80, or it is difficult to secure a plurality of blowers 60. Therefore, the third embodiment can be an effective method for manufacturing structures in the scenario of manufacturing temporary housing in disaster-stricken areas or developing countries.

[0054] In the above, the method of regulating only the outer shape of the side surface 30 of the structure 1 has been described. However, the part for regulating the outer shape is not limited to the side surface 30, and the front surface 20, the back surface 40, and the ceiling 50 may be regulated. It is clear from the description of the claims that forms with such changes or improvements can also be included in the technical scope of the present invention.

Explanation of Reference Numerals

[0055] 1 Structure 10 Outer skin member 11 Inner wall member 12 Stitching 20 Front surface 21 Access hole 30 Side surface 31 Communication part 40 Back surface 41 Air inlet hole 50 Ceiling 60 Blower 71 Peg 80 Outer shape regulation jig

Claims

1. A method for manufacturing a structure, comprising: feeding gas inside a skin member that forms the outer shape of the structure to inflate the skin member; attaching an inner wall member to the inner surface of the inflated skin member to form an inner wall while restricting the bulge of a part of the inflated skin member from the outside; the restriction from the outside forms at least one wall of the structure; A method for manufacturing a structure, wherein the wall is perpendicular to the ground.

2. The method for manufacturing a structure according to claim 1, wherein the restriction from the outside is performed by a bag body into which gas is fed and which is in contact with the inflated skin member. The method for manufacturing a structure according to claim 1.

3. The method for manufacturing a structure according to claim 2, wherein the bag body is a skin member different from the skin member. The method for manufacturing a structure according to claim 2.

4. The method for manufacturing a structure according to claim 2 or 3, comprising forming a communication part that communicates the skin member and the bag body. The method for manufacturing a structure according to claim 2 or 3.

5. The method for manufacturing a structure according to claim 4, comprising separating the communication part after forming the inner wall with the inner wall member. The method for manufacturing a structure according to claim 4.

6. The method for manufacturing a structure according to claim 5, comprising forming a window of the structure at the separation location of the communication part. The method for manufacturing a structure according to claim 5.

7. The method for manufacturing a structure according to any one of claims 1 to 6, wherein the ceiling of the structure is formed by the restriction from the outside. The method for manufacturing a structure according to any one of claims 1 to 6.

8. The method for manufacturing a structure according to any one of claims 1 to 6, wherein opposing side surfaces of the structure are formed by the restriction from the outside. The method for manufacturing a structure according to any one of claims 1 to 6.

9. A method for manufacturing a plurality of structures, comprising: arranging skin members that form the outer shapes of the plurality of structures side by side, feeding gas inside each of the skin members, and inflating them; while restricting the bulge of a part of the skin member by another adjacent skin member, attaching an inner wall member to the inner surfaces of the restricted plurality of skin members to form inner walls; the restriction from the adjacent other skin member forms at least one wall of the plurality of structures; A method for manufacturing a plurality of structures, wherein the wall is perpendicular to the ground.

10. The method for manufacturing a plurality of structures according to claim 9, wherein the skin member and at least one of the adjacent other skin members are communicated by a communication part. The method for manufacturing a plurality of structures according to claim 9.

11. The method for manufacturing a plurality of structures according to claim 10, comprising separating the communication part after forming the inner walls with the inner wall members. The method for manufacturing a plurality of structures according to claim 10.

12. A step of forming windows of the plurality of structures at a separation location of the communication portion is included. The method for manufacturing a plurality of structures according to claim 11.

13. Forming the ceiling of the plurality of structures by the restriction from the other adjacent outer skin member. The method for manufacturing a plurality of structures according to any one of claims 9 to 12.

14. Forming the opposing side surfaces of the plurality of structures by the restriction from the other adjacent outer skin member. The method for manufacturing a plurality of structures according to any one of claims 9 to 12.

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