Chamber element preform and method

Abstract

A chamber element preform (1) is adapted to produce a pressure formed structure (8). The preform includes a first wall (2) and a second wall (3) each comprised of metal sheet. The first and second walls of the preform are arranged to provide a transverse gap (22) between the walls, and the respective edges of the walls are engaged in fluid tight relation by a seal (6) to produce a fluid tight inner space (4) that includes the gap. An expansion substance (7) housed within the inner space is operative to undergo a physical and / or chemical transition that is initiated from outside the preform. The transition is operative to cause fluid pressure within the inner space that permanently deforms one or more of the walls. A valve (26, 28) may be utilized to relieve fluid pressure within the inner space that is above a selectively adjustable set threshold to control a final shape of the pressure formed structure.

Description

TECHNICAL FIELD

[0001] Exemplary arrangements relate to structural and / or to decorative products and methods of manufacturing such products. Exemplary arrangements relate to chamber element preforms that are adapted to produce through pressurization of the chamber and deformation of the walls of the preform, pressure formed structures. Such chamber element preforms may be utilized in building construction, vehicle manufacturing, furniture manufacturing or for producing ornamental or decorative items.BACKGROUND

[0002] Chamber element preforms comprised of metal sheets that bound a fluid tight chamber or cavity, may be deformed through the application of fluid pressure to the cavity to produce structural or decorative items having desired pressure formed final shapes. Such preforms may be utilized in various fields. Such fields include structural elements for buildings. Such preforms may be used in the production of wall panels, ceilings, doors or other structures utilized in construction of buildings. Such chamber element preforms may also be used in the manufacture of vehicle parts. Such parts may include frames, bodies, doors or hoods. Furniture structures may also be produced using chamber element preforms. Such furniture structures may include structural members or decorative elements. Numerous different types of ornamental or decorative pressure formed structures may be produced using chamber element preforms.

[0003] In some situations the production of pressure formed structures using chamber element preforms may be challenging due to the need to achieve high dimensional accuracy and / or desired properties of the final pressure formed structures. In some exemplary arrangements it may be difficult to consistently produce identically shaped final structures using such preforms due to variations in applied pressures to the chambers of the preforms. Further, in some situations it may be difficult to utilize such preforms at the site where the final pressure formed structures will be used due to the difficulty in providing the necessary equipment at the site to pressurize the chambers of the preforms as necessary to produce the final structures.

[0004] Chamber element preforms and methods of producing such items may benefit from improvements.SUMMARY

[0005] Exemplary arrangements include chamber element preforms that are adapted to produce pressure formed structures having desired final shapes. Exemplary chamber element preforms may be utilized to produce numerous different types of structures including those utilized in building construction, vehicle, furniture and / or decorative applications.

[0006] An exemplary chamber element preform includes a first wall that is comprised of metal sheet that is bounded by a first wall edge. The preform also includes a second wall comprised of metal sheet that is bounded by a second wall edge. The first wall and the second wall are arranged so that the edges correspond and a transverse gap extends between the walls within the preform. The transverse gap extends between a respective first inner wall surface of the first wall that is in facing relation with the second wall, and a respective second wall surface of the second wall that is in facing relation with the first wall.

[0007] In the exemplary arrangements a seal is operative to join the first wall edge and the second wall edge. The seal is operative to join the wall edges in fluid tight relation. The seal is operative to bound a fluid tight inner space within the preform that includes the gap. The inner space is bounded by the seal and the first wall inner surface and the second wall inner surface.

[0008] The exemplary preform includes an expansion substance that is housed within the inner space. In exemplary arrangements the expansion substance is adapted to undergo a physical and / or a chemical transition within the inner space. The transition of the expansion substance within the inner space is caused to be initiated from outside the preform. The physical and / or chemical transition is operative to cause positive fluid pressure within the inner space sufficient to cause permanent deformation of one or more of the first wall or the second wall. The permanent deformation of the first and / or second wall of the preform responsive to the force generated in the inner space is operative to produce the pressure formed structure having a final desired shape.

[0009] In exemplary arrangements the chamber element preform includes a valve, the exemplary valve is in fluid connection with the inner space of the preform. The exemplary valve is operative to cause fluid pressure that is produced within the inner space due to the transition of the expansion substance that is above a set threshold pressure, to escape from the inner space to outside the preform through the valve. The valve enables the set threshold pressure to be selectively adjustable. Selectively adjusting the set threshold pressure is operative to control the amount of permanent deformation of the walls of the preform to control the final shape of the product.

[0010] In some exemplary arrangements the initiation of the transition is carried out from outside the preform by heating the preform above ambient temperature. In other exemplary arrangements the transition is initiated by cooling of the preform below ambient temperatures. In other exemplary arrangements initiation of the transition may be caused by externally applied vibrations, mechanical shocks or deformation of the preform. In some exemplary arrangements one or more materials which are included in the expansion substance may be added to the inner space after much of the structure of the preform is produced. Further in some exemplary arrangements the location of the expansion substance, or the amount in selected locations within the inner space, may facilitate the desired pressure induced deformation to achieve a desired shape of the pressure formed structure.

[0011] Exemplary arrangements further include methods of making the described chamber element preforms.

[0012] Further features of exemplary arrangements are described in the following Detailed Description and the appended drawings.BRIEF DESCRIPTION OF DRAWINGS

[0013] FIG. 1 is a front view of an exemplary chamber element preform.

[0014] FIG. 2 is a transverse cross-sectional view of the chamber element preform shown in FIG. 1.

[0015] FIG. 3A is a cross-sectional view of the exemplary chamber element preform of FIG. 1 with the walls in an undeformed condition.

[0016] FIG. 3B is a cross-sectional view of a preform of FIG. 3A with the walls thereof permanently deformed due to the application of fluid pressure.

[0017] FIG. 3C is a cross-sectional view of the preform of FIG. 3B with the walls thereof further permanently deformed due to the application of fluid pressure.

[0018] FIG. 3D is a cross-sectional view of the preform of FIG. 3C with the walls thereof further permanently deformed due to the application of fluid pressure.

[0019] FIG. 3E is a cross-sectional view of the preform of FIG. 3D with the walls thereof further permanently deformed due to the application of fluid pressure.

[0020] FIG. 3F is a cross-sectional view of the preform of FIG. 3E with the walls thereof further permanently deformed due to the application of fluid pressure to produce a final pressure formed structure.

[0021] FIG. 4 is a front plan view of the final pressure formed structure produced from the preform shown in FIG. 1.

[0022] FIG. 5 is a side view of the final pressure formed structure shown in FIG. 4.

[0023] FIG. 6 is a perspective view of the chamber element preform of FIG. 1 after it has been pressurized to produce the final shape of the pressure formed structure.

[0024] FIG. 7 is a front view of an alternative exemplary chamber element preform.

[0025] FIG. 8 is a side cross-sectional view of the alternative chamber element preform.

[0026] FIG. 8A is an enlarged view of the circled portion of the preform shown in FIG. 8.

[0027] FIG. 9A is a cross-sectional view of the exemplary chamber element preform of FIG. 7 with the walls thereof in an undeformed condition.

[0028] FIG. 9B is a cross-sectional view of the preform of FIG. 9A with the walls thereof permanently deformed as a result of fluid pressure.

[0029] FIG. 9C is a cross-sectional view of the preform of FIG. 9B with the walls thereof further permanently deformed as a result of fluid pressure.

[0030] FIG. 9D is a cross-sectional view of the preform of FIG. 9C with the walls thereof further permanently deformed as a result of fluid pressure

[0031] FIG. 9E is a cross-sectional view of the preform of FIG. 9D with the walls thereof permanently deformed as a result of fluid pressure to produce a final pressure formed structure.

[0032] FIG. 10 is a front view of the final pressure formed structure shown in FIG. 9E.

[0033] FIG. 11 is a side view of the final pressure formed structure shown in FIG. 9E.

[0034] FIG. 12 is a top view of the final pressure formed the structure shown in FIG. 9E.

[0035] FIG. 13 is a perspective view of the final pressure formed structure produced using the chamber element preform of FIG. 7.

[0036] FIG. 14A is a cross-sectional view of a further alternative chamber element preform in attached connection with a load bearing column.

[0037] FIG. 14B is a cross-sectional view of the preform of FIG. 14A with a wall thereof permanently deformed as a result of fluid pressure.

[0038] FIG. 14C is a cross-sectional view of the preform of FIG. 14B with the wall thereof further permanently deformed as a result of fluid pressure.

[0039] FIG. 14D is a cross-sectional view of the preform of FIG. 14C with the wall thereof further permanently deformed as a result of fluid pressure to a final form structural shape.

[0040] FIG. 14E is a cross-sectional view of the preform of FIG. 14D with an expansion substance shown condensed therein.

[0041] FIG. 15A is a cross-sectional view of a further chamber element preform in attached connection with a load bearing column.

[0042] FIG. 15B is a cross-sectional view of the chamber element preform of FIG. 15A with the wall thereof deformed as a result of fluid pressure.

[0043] FIG. 15C is a cross-sectional view of the chamber element preform of FIG. 15B with the wall thereof deformed as a result of fluid pressure to a final formed structural shape.

[0044] FIG. 16 is a perspective view of the chamber element preform of FIG. 15A subsequent to undergoing pressure deformation.

[0045] FIG. 17 is a cross-sectional schematic view of an exemplary adjustable pressure relief valve in attached fluid connection with the inner space of the chamber element preform via a releasable fluid coupling.

[0046] FIG. 18 is a cross-sectional schematic view similar to FIG. 17 showing an alternative exemplary valve arrangement.DETAILED DESCRIPTION

[0047] Referring now to the drawings and particularly to FIG. 1 there is shown therein an exemplary chamber element preform generally indicated 1. The exemplary chamber element preform includes a first wall 2 comprised of deformable metal sheet. The exemplary first wall has a generally square shape. The exemplary first wall includes an edge 14 that bounds the outer periphery of the wall 2.

[0048] The exemplary preform further includes a second wall 3. The second wall is also comprised of deformable metal sheet and has a generally square shape that corresponds to the shape of the first wall. The second wall 3 includes an edge 16 that bounds the outer periphery of the second wall 3.

[0049] In the exemplary arrangement the edge 14 of the first wall and the edge 16 of the second wall are arranged in closely aligned relation. A first wall inner surface 18 of the first wall 2 is positioned in facing relation with the second wall 3. A second wall inner surface 20 of the second wall 3 is positioned in facing relation with the first wall such that a transverse gap 22 extends between the first wall inner surface and the second wall inner surface. In the exemplary arrangement in transverse cross-section the first wall inner surface 18 and the second wall inner surface converge so as to be closer together with increased proximity to the respective edges 14, 16.

[0050] In the exemplary arrangement a seal 6 is operative to join the first wall edge 14 and the second wall edge 16 in sealed fluid tight relation. As a result the seal 6, the first wall inner surface 18 and the second wall inner surface 20 bound a hermetically sealed pressure tight inner space 4 which includes the transverse gap 22. In exemplary arrangements the seal 6 comprises a continuous seal that extends continuously at the peripheral edges 14, 16 of the walls of the preform. The sealed inner space may alternatively be referred to herein as a chamber or a cavity. In exemplary arrangements the seal may comprise one or more of a weld such as a fusion weld or a pressure weld, an adhesive layer, a soldered joint, a glued joint, a crimped joint, a pressed joint or a lap joint or other suitable seal type for producing a fluid tight seal suitable for holding fluid pressure within the inner space sufficiently high to cause deformation of at least one the first wall or the second wall of the preform to produce the desired final pressure formed structure.

[0051] The exemplary preform includes an expansion substance 7 housed within the inner space 4. In exemplary arrangements the expansion substance comprises one or more materials that are operative to undergo a physical and / or a chemical transition. In exemplary arrangements the transition which the expansion substance is caused undergo in the inner space is initiated from outside the preform. The transition is operative to cause positive fluid pressure within the inner space 4 that is sufficient to cause deformation of the one or more of the first and second walls so as to produce the formed structure having the final desired shape.

[0052] For purposes of this disclosure an expansion substance shall be defined as one or more materials that undergo a physical and / or a chemical transition. For purposes hereof a transition is defined as one or more of a change in chemical or physical properties, a change in phase, a change in composition and / or a change in volume. In exemplary arrangements in response to a transition, the expansion substance is operative to one or more of increase in volume, and / or to generate heat, and / or to generate gas, and / or to generate vapor so as to produce elevated positive pressure within the inner space that is sufficient to cause permanent wall deformation to produce the desired final shape with the pressure formed structure.

[0053] In exemplary arrangements the expansion substance may include materials such as water, an alcohol, a mixture of two or more alcohols, glycerin, an iron and copper(II) oxide combination, blowing agents suitable for producing gas or expansion such as to produce foam plastics including chemical blowing agents and / or physical blowing agents. Exemplary expansion substances may further include materials that produce gas evolving or gas forming reactions. Exemplary expansion substances may further include materials that expand physically in response to initiation.

[0054] In exemplary arrangements initiation from outside the preform may include exposure of the preform to an elevated temperature that is above ambient temperature which is operative to cause the expansion substance within the preform to undergo a transition. An alternative arrangements initiation may include exposure of the preform to temperatures below ambient temperature which cause the expansion substance within the inner space to undergo a transition.

[0055] In some exemplary arrangements the heating or cooling above and / or below ambient temperature may cause melting, fracture, disintegration or other form of breakage of a container within the inner space which houses one or more of the materials which make up the expansion substance, which breakage causes the release and mixing of such materials to cause the transition. In other exemplary arrangements other types of initiation may include subjecting the preform to vibration. In some such exemplary arrangements vibration is operative to liquefy and / or mix one or more materials which are included in the expansion substance so as to cause initiation of a transition. In some exemplary arrangements vibration may be operative to fracture, open or otherwise cause breakage of the container housing within the inner space of one or more materials which comprise the expansion substance, which vibration causes a chemical or other reaction to occur within the inner space. In other exemplary arrangements initiation may include subjecting the preform to mechanical shock. The mechanical shock may cause mixing of materials which comprise the expansion substance so as to cause a transition. Alternatively and / or in addition initiation caused by subjecting the preform to mechanical shock may cause fracture, disintegration, loss of integrity or other breakage of one or more containers within the inner space which results in mixing or combination of the materials of the expansion substance that were previously physically separated within the inner space so as to cause a transition.

[0056] Further in some exemplary arrangements initiation of the transition from outside the preform may include deformation of the preform. This may include for example temporary deformation such as bending, or permanent deformation such as denting, a portion of a wall or other structure which is operative to cause fracture, disintegration, loss of integrity or other breakage of a container housing one or more physically separated materials of the expansion substance. The deformation of the preform is operative to cause the separated materials of the expansion substance to no longer be physically separated resulting in the physical and / or chemical transition.

[0057] Of course these manners of initiation from outside the preform to cause a transition of the expansion substance while useful, are exemplary and in other arrangements other manners of initiation for a transition may be used.

[0058] In exemplary arrangements a method of making the exemplary chamber element preform 1 includes the steps of providing the first wall 2 including the first wall edge 14, and providing the second wall 3 including the second wall edge 16. The method further includes arranging the first wall and the second wall with the edges thereof in an adjacent and closely aligned relation and so that the transverse gap 22 extends between the first wall inner surface 18 and the second wall inner surface 20. In the exemplary method the first wall and the second wall are arranged such that the first wall inner surface and the second wall inner surface are convergent so as to be closer together with increased proximity to the respective edges of the walls.

[0059] The exemplary method of producing the preform 1 further includes providing the expansion substance 7 so that it is positioned and caused to be housed within the preform in the inner space that includes the transverse gap and that is bounded by the respective inner surfaces of the walls and the seal 6. As previously discussed in some exemplary arrangements providing the expansion substance may include providing different materials which make up the expansion substance within one or more containers that are operative to maintain the materials of the expansion substance physically separated prior to actions which comprise initiation.

[0060] The exemplary method of making the exemplary chamber element preform 1 further includes joining the first wall edge and the second wall edge in fluid tight relation via the seal. In the exemplary arrangement the wall edges may be joined by a seal in one of the ways previously discussed such that a fluid tight inner space which includes the gap is bounded by the continuous seal. The inner space extends between the seal 6, the first wall inner surface 18 and the second wall inner surface 20. In the exemplary arrangement the expansion substance is housed within the fluid tight inner space such that the transition of the expansion substance can be initiated from outside the preform which causes the increase in fluid pressure within the inner space and the deformation of the walls of the preform so as to produce the final pressure formed structure.

[0061] As previously mentioned in some exemplary arrangements the expansion substance may be selectively positioned within the inner space in certain ways that facilitate controlled deformation of areas of the walls of the preform so as to produce from the preform the desired final pressure formed product shape. This may include for example positioning the expansion substance, selected amounts of the expansion substance or certain materials included in the expansion substance, in selected areas of the walls so as to generate heat, areas of higher pressure, or other properties during the transition in those selected areas within the inner space so that the deformation occurs in a desired manner that results in the desired final shape. Numerous different approaches to the selective positioning or arrangement of the expansion substance may be utilized depending on the particular chamber element preform configuration, the expansion substance and the desired final product shape.

[0062] In the exemplary arrangement using the chamber element preform 1 an expansion substance 7 which consists of an alcohol (polyol) such as glycerin is positioned within the inner space 4. The preform of this exemplary arrangement may be approximately 10 cm in height and maintained at an ambient temperature below 20° C to maintain the glycerin in a non-vapor state. In the exemplary arrangement several grams of glycerin are included in the inner space.

[0063] As represented in FIGS. 3A through 3E a transition of the expansion substance is initiated by exposing the exterior of the preform to a temperature above ambient temperature. In the case of the chamber element preform which houses glycerin as the expansion substance, the preform is heated above the ambient temperature of about 20° C. Heating of the exemplary preform is operative to cause the transition of the expansion substance. In the exemplary arrangement the preform is heated within a furnace and heated to an elevated temperature which ensures that the glycerin which serves as the exemplary expansion substance, is boiled and that vapors are generated to increase pressure in the inner space. In some exemplary arrangements the transition is carried out by heating the preform in a furnace at a temperature of 300° C for a period of 10 minutes.

[0064] The transition of the expansion substance and the generation of vapors produces elevated pressure within the fluid tight inner space 4. The increase in pressure within the inner space causes the permanent deformation of the first wall 2 and the second wall 3 as shown in FIGS. 3A-3E to cause the preform to become the final shape for the pressure formed structure 8 which is comprised of the deformed chamber element. Thereafter removing the pressure formed structure 8 from the furnace and cooling the formed structure to ambient temperature is operative to cause the walls to remain in the deformed condition. The expansion agent 7 may re-condense within the inner space and return to a liquid or solid condition depending on the ambient temperature as represented in FIG. 3F.

[0065] As shown in FIGS. 3F, and 4 through 6 the exemplary preform undergoes the greatest deformation in the walls in the central regions of the first wall 2 and the second wall 3 in the areas that are the furthest distance from the seals. In this exemplary arrangement the smallest amount of deformation of the walls occurs in regions that are closest to the seal 6.

[0066] It should be understood that in the exemplary arrangement the pressure formed structure 8 produced through deformation of the preform 1 is symmetrical in that each of the walls are deformed in the same amount and in the same manner. It should be understood however that in other arrangements different shapes may be produced by providing different thicknesses of metal sheet for the walls or differing thicknesses in disposed areas of a single wall.

[0067] Further it should be understood that the use of glycerin as the expansion substance is merely an example of expansion substances that may be used. For example in other exemplary arrangements the expansion substance may comprise 60% ethyl alcohol. The transition of this expansion substance to a vapor to produce a pressure necessary to achieve the pressure formed structure 8 may be lower. For example using the 60% ethyl alcohol as the expansion substance may produce an internal pressure in the inner space to produce deformation of the preform comparable to that produced by glycerin as previously discussed, by external heating of the preform for a period of about 10 minutes at 100° C. Of course numerous other expansion substances of the types previously discussed may be used in other arrangements.

[0068] An alternative chamber element preform and the pressure deformation thereof to produce a final pressure formed structure is shown in FIGS. 7 through 13. In this alternative exemplary arrangement the features of the alternative preform that are common features with the previously described chamber element preform 1 will be referred to utilizing the same reference numbers.

[0069] In the exemplary chamber element preform shown in FIG. 7 the first wall 2 and the second wall 3 have edges that cause the preform to correspond to a star shape. In the exemplary arrangement the final shape of the pressure formed structure produced by deformation of the preform may be used as a decoration or ornamentation which can be hung by a hanger or secured to flat surfaces.

[0070] In this exemplary arrangement the structures which comprise the chamber element preform are substantially the same as those in the previous chamber element preform arrangement with the exception of the configuration of the edges of the first wall and the second wall. Further the steps carried out in a method for manufacturing the chamber element preform shown in FIGS. 7 - 13 may be generally the same as those discussed in connection with the prior preform except as otherwise stated.

[0071] Unlike the previously described chamber element preform, the preform shown in FIGS. 7 and 8 includes an opening 24 in the first wall 2. The opening 24 serves as a fluid opening to the fluid tight inner space 4. It should be understood that in other arrangements the opening 24 could be in the second wall 3 rather than in the first wall. Further the exemplary opening is in generally centered relation of the first wall 2. This is done in the exemplary arrangement to achieve a centered distribution of pressure within the inner space 4 of the preform. However it should be understood that the opening may be in other positions on the wall in other arrangements. In some exemplary alternative arrangements the opening may be provided in other selected positions in order to produce certain desired uneven pressure distributions or other properties that are utilized to produce a particular pressure formed structure shape from the preform.

[0072] In the exemplary arrangement a coupling 5 is in fixed fluid tight connection with the first wall. The coupling is in fluid communication with the opening 24. In the exemplary arrangement the coupling is a releasable fluid coupling such as a threaded coupling, a bayonet coupling or other suitable releasable coupling adapted for joining components in fluid tight relation. In the exemplary arrangement the coupling is adapted to be in releasable engagement with a valve 26 such as is shown schematically in FIG. 17. In other exemplary arrangements the fluid coupling may be releasably connected with an alternative valve 28 such as is shown schematically in FIG. 18.

[0073] It should be understood however that although in the exemplary arrangement the coupling 5 is shown as fluidly connected directly to a valve, in other arrangements the coupling may be adapted to connect to a suitable fluid conduit or other device. It should be appreciated that the exemplary coupling may be utilized to pass fluid into the fluid tight inner space 4 or outward from the fluid tight inner space 4 to the outside of the preform.

[0074] In the exemplary preform shown in FIGS. 7 and 8 the coupling 5 may operate to perform two functions. The coupling may be utilized to deliver at least one material of the expansion substance into the inner space 4. As can be appreciated in some exemplary arrangements it may be useful to introduce the expansion substance or one or more component materials thereof into the fluid tight inner space after the first wall and the second wall have been engaged by formation of the seal 6. This may be particularly true in situations where the formation of the seal may expose the area of seal formation to excessive heat. Alternatively in other arrangements it may be desirable to avoid the introduction of the expansion substance into the inner area until after an adhesive or a substance utilized in producing a glued joint has fully cured.

[0075] In some exemplary arrangements the valve may comprise an adjustable pressure relief valve such as the valve 26 as schematically represented in FIG. 17. Such a valve is operative to cause fluid pressure above a set threshold pressure to escape through the opening 24 and the coupling 5 from the inner space 4 to an opening 48 in the body of the value to the outside of the preform. In the exemplary arrangement the set threshold pressure at which the valve 26 will release the pressure from the inner space is selectively adjustable. This may be done in some arrangements by turning a knob, turning a valve element with a tool, or by adjusting other pressure setting elements of the valve. Adjustment of the set threshold pressure is operative to control an amount of deformation of the first wall and / or second wall and thereby control the final shape of the pressure formed structure. In some exemplary arrangements valve 26 may comprise or include the features of a field adjustable pressure relief valve such as those commercially available from HiP of Erie PA, The Lee Company of Westbrook CT and Parker Hannifin Corporation of Cleveland OH.

[0076] In this exemplary arrangement the expansion substance 7 is comprised of at least one material that is maintained physically separate from at least one other material of the expansion substance by being maintained within one or more containers 30 as represented for example in FIG. 8A. In exemplary arrangements different materials of the expansion substance are maintained physically separate prior to initiation of the transition by being stored within the inner space in separate sealed containers.

[0077] Further in some exemplary arrangements because the coupling enables the valve to be releasably connected to the preform, one or more of the materials housed within containers which make up the expansion substance may be delivered into the inner space through the coupling when the valve has been disengaged from the coupling. This may be operative to provide additional area through which the containers including at least a portion of the expansion substance may be introduced into the inner space. The valve may then be reengaged with the coupling to close the opening in the wall and the inner space once the expansion substance has been placed within the preform.

[0078] In some exemplary arrangements the containers may be comprised of a frangible material such as a thin glass which is subject to breakage in response to initiation from outside the preform such as via shock, vibration or deformation of one or more of the walls 2, 3 in the area of the containers. In such exemplary arrangements the initiation from outside the preform is operative to break the containers causing release and mixing of the materials held therein so as to produce the transition which causes the increased pressure within the inner space 4. In exemplary arrangements the materials which make up the expansion substance when mixed initiate a chemical reaction resulting in increased volume of the expansion substance and the generation of gas, heat and / or vapors which provide for the pressurization of the inner space and the deformation of at least one of the first wall of the second wall so as to produce the shape of the final pressure formed structure 8.

[0079] Alternatively in other arrangements the containers 30 which house the one or more materials of the expansion substance which need to be physically separated prior to initiation, may be comprised of a material that can be broken by being liquefied or disintegrated in response to external initiation. This may include in some arrangements containers comprised of a thin plastic or another material which melts responsive to initiation which includes exposure of the preform to an elevated temperature above ambient temperature. Further in other exemplary arrangements materials of the expansion substance which need to be physically isolated may be housed in containers that break via fracture or otherwise lose their structural integrity in response to response to vibration, shock, sonic excitation or other types of initiation from outside the preform.

[0080] Further in other exemplary arrangements a preform may be produced with a container that is encapsulated in fixed connection with an area of an inner surface of a wall that may be subject to temporary or permanent deformation such as by being manually bent or by being struck with a hammer or other tool. Deformation of the wall may be operative to break the container so as to release the material housed therein and to cause exposure and mixing with other materials of the expansion substance so as to cause the transition. It should be understood that in some exemplary arrangements some containers for maintaining a particular material of the expansion substance may be placed in the inner space prior to the inner space being sealed such as in the first described exemplary arrangement, while other materials or compounds-of the expansion substance may be later introduced to the inner space through the coupling 5 after the preform seal 6 has been produced.

[0081] As can be appreciated and as represented in FIGS. 9A through 9E, the pressurization within the inner space 4 causes the deformation of the first wall 2 and the second wall 3. As shown in these Figures, the preform is shown without the valve 26 in attached connection with the coupling 5 for purposes of simplicity. However it should be understood that in this exemplary arrangement the preform undergoes deformation with the valve 26 installed to control the pressure within the inner space and to also control the shape of the final pressure formed product.

[0082] As previously discussed numerous different types of expansion substances may be utilized in exemplary arrangements. An example of a pair of materials which when combined results in an increase in volume and in the generation of heat and vapors are an alcohol such as a polyol, and isocyanate which when combined produce a chemical reaction producing a polyurethane foam. In this exemplary arrangement the resulting foam produces fluid pressure within the inner space 4 which causes deformation of the walls of the preform. The pressure produced is controlled by the set threshold pressure of the valve 26 to assure that the deformation of the walls of the preform occur in the desired manner so as to produce the final pressure formed structure 8. Of course it should be understood that these substances for producing polyurethane foams are exemplary and in other arrangements other types of foams may be produced through the use of other chemical blowing agents, physical blowing agents or substances that react to produce a gas to produce a foam or other cellular material.

[0083] In other exemplary arrangements the expansion substance may be comprised of two or more materials that when combined are operative to cause a transition that results in a volume increase and / or vapor generation in the fluid tight inner space 4. The increased pressure in the inner space is operative to deform at least one of the first wall or the second wall of the chamber element preform to produce the desired final shape of the pressure formed structure. An example of such compounds that can be physically separated in containers during storage within the inner space prior to initiation and transition include iron and copper (II) oxide. The combination of these materials as a result of initiation causes a chemical reaction which results in the reduction of the iron and the oxidation of the copper. The chemical reaction produces significant heat within the inner space that can be used to boil fluid or vaporize other materials that may be included in the inner space as part of the expansion substance. Such heat and vapors result in elevated pressures and temperatures which facilitate the deformation of the walls to produce the final shape of the pressure formed structure. Further in the exemplary arrangement the amount of pressure produced by the expansion substance is maintained at no greater than the set threshold pressure by the adjustable pressure relief valve 26.

[0084] As can be appreciated the selective adjustment of the set threshold pressure of the valve 26 enables selective control of the degree of deformation of the walls of the preform and the shape of the final resulting pressure formed structure. In exemplary arrangements the valve 26 enables control of the pressure which is achieved within the inner space 4 and avoids instances of overpressure that might result from variations in amounts or properties of the materials that are included in the expansion substance. Further in exemplary arrangements the valve 26 is further operative to avoid overpressure conditions that might otherwise occur and result in rupture of the preform structure which could result in damage or physical harm. Of course it should be understood that while these approaches are useful they are exemplary and in other arrangements other approaches may be used.

[0085] In other alternative arrangements water may be used as an expansion substance which produces increased fluid pressure as a result of being cooled to below ambient temperature. The expansion of water as it changes phase from a liquid to a solid may be utilized to produce increased fluid pressure within the inner space of the preform to cause deformation of the walls to produce the shape of the pressure deformed preform structure.

[0086] In an exemplary arrangement the chamber element preform may have the inner space thereof substantially filled with water. The transition which comprises changing the water from the liquid phase to the solid phase is initiated by placing the preform in a freezer or other suitable device which cools the water to a temperature below freezing. For example in an exemplary arrangement the preform may be exposed to a temperature of -6° C for a period of two hours. In this exemplary arrangement the change in phase of the water increases the fluid pressure in the inner space and deforms the walls of the preform responsive to the expansion of the water as it changes phase. The change in phase produces the desired shape for the final pressure formed structure.

[0087] It should be understood that in some exemplary arrangements once the preform has been deformed due to fluid pressure, the pressure formed structure 8 may be returned to room temperature or heated to an elevated temperature which results in melting of the ice present within the inner space. In exemplary arrangements the valve may be removed from the coupling to further facilitate this process and avoid any risk of undesirable collapse of the deformed structure. Removal of the valve also enables the water to be drained through the coupling from the inner space.

[0088] Further in some exemplary arrangements after valve removal the coupling may be utilized as a mounting structure for the final pressure formed structure. In some exemplary arrangements the coupling or the threads thereon may enable the structure to be engaged with a mount or a hanger to enable the structure to be positioned as desired by the user.

[0089] Further in other exemplary arrangements a valve of the type represented in FIG. 18 may alternatively be used. In this exemplary arrangement valve 28 includes an adjustable pressure relief valve portion 32 that functions in a manner similar to valve 26. Valve portion 32 fluidly connects the coupling 5 and a fluid outlet 34 on the body of the valve.

[0090] The exemplary valve 28 further includes a fluid introduction port 36 on the exterior of the body of the valve. In the exemplary arrangement the fluid introduction port 36 is adapted to be selectively closed by a removable plug 38. When the plug is not installed, the fluid introduction port is adapted to receive at least one material of the expansion substance therethrough. The valve body includes an internal passage 40 which is operative to direct the fluid received through the fluid introduction port to the coupling 5 and through the opening 24 in the wall to the inner space 4. In the exemplary arrangement a check valve 42 is included in the fluid passage 40 to assure that the fluid can only pass in one direction through the fluid passage and that pressure cannot escape from the inner space through the passage 40. Installation of the plug further assures that no pressure may escape through the passage. Of course it should be understood that this approach while useful for introducing at least one material of the expansion substance into the inner space, it is exemplary and in other arrangements other approaches may be used.

[0091] Further in this exemplary arrangement the valve 28 further includes a safety pressure relief valve portion schematically indicated 44. The safety pressure relief valve portion is operative to cause fluid pressure in the inner space that is above a fixed high pressure threshold to be released through the valve to the outside of the preformed independent of the set threshold pressure of the adjustable pressure relief valve portion 32. In exemplary arrangements the safety pressure relief valve portion 44 is operative to assure that excessively high pressure which might cause rupture of the preform is not developed within the inner space as a result of a malfunction of the adjustable pressure relief valve 32 or from other causes.

[0092] In some arrangements the valve portions of valve 28 may be integrated within a single valve body as shown and in other arrangements the valve 28 may be comprised of multiple fluid connected valve bodies and fittings. Suitable valves and fittings are commercially available from the suppliers of pressure relief valves previously mentioned herein.

[0093] Of course it should be understood that the structures and functions of valve 28 while useful, are exemplary and in other arrangements different or other structures and functions may be provided.

[0094] FIGS. 14A through 14E show a further alternative exemplary arrangement of a chamber element preform that is shown in a cross-sectional view undergoing deformation as a result of increased internal fluid pressure in the inner space. In this exemplary arrangement structures similar to those previously discussed are represented using the same reference numbers for simplicity. Further it should be understood that although it is not shown in the Figures, a valve, such as valve 26 or valve 28 may be in attached fluid connection with the coupling 5 of the preform.

[0095] This exemplary chamber element preform may be utilized as a fire barrier that is operative to protect heat vulnerable load bearing elements of a building such as a load bearing column 9. FIGS. 14A through 14E show cross-sections of the preform as the second wall 3 is deformed responsive to an increase in pressure in the inner space 4 of the preform. In exemplary arrangements preform may be manufactured in accordance with a method similar to that previously described, and may be secured to an external surface of the load bearing column 9 by suitable fastening methods. As can be appreciated, multiple preforms may be utilized by being positioned in multiple different areas and / or on multiple sides of the load bearing column. Of course it should be understood that in other arrangements suitable preform structures may be attached to load bearing columns or other structures to be fire protected on site through suitable fasteners which do not destroy the fluid tight character of the inner space of the preforms.

[0096] The exemplary chamber element preform and the expansion substance housed therein provide a ready to use fire barrier for a load bearing column or other fire protected structure to which the preform is attached. In the case of a fire spreading in the vicinity of the load bearing column 9, a transition of the expansion substance 7 housed within the preform is initiated by the exposure of the preform to the elevated temperature produced by the fire. The initiation of the transition causes an increase in pressure within the fluid tight inner space. This can be accomplished in exemplary arrangements such as by the increased temperature causing boiling and an increase vapor pressure within the inner space of the preform. In exemplary arrangements because the deformation of the first wall 2 is limited by engagement with a surface of the load bearing column 9, a greater amount of deformation of the second wall 3 may occur in accordance with the set threshold pressure of the associated valve. In some exemplary arrangements the deformation of the second wall 3 to produce the pressure formed structure 8 causes the column to be shielded from direct contact with the fire which reduces the temperature to which the column is exposed.

[0097] Further as shown in the exemplary arrangement the coupling 5 and the valve in connection therewith is disposed within a passage 46 within the column 9. In this exemplary arrangement this configuration enables the first wall 2 to not only be flush and in contact with the column, but also shields the valve and enables any excess pressure and the expansion substance to be released through the passage 46 which may also provide for a further cooling effect within that region of the column.

[0098] As shown for example in FIG. 14E after the pressure formed structure 8 has been produced as a result of the expansion within the inner space 4, an expansion substance that has undergone a transition to a vapor may recondense within the inner space to a liquid or a solid. In exemplary arrangements this may enable further expansion of the inner space in the event that the fire condition and an elevated temperature recurs within the area of the load bearing structure. Of course it should be understood that this exemplary arrangement while useful, is exemplary and in other arrangements other preform configurations and structures may be used.

[0099] Further in other exemplary arrangements an expansion substance in the form of a foam producing expansion substance may be utilized. Such foam producing substances may undergo a transition to produce materials with insulating properties and / or fire retardant properties. For example in some exemplary arrangements the expansion substance may include materials such as a polyol and isocyanate which are maintained physically separated in containers within the inner space of the preform at normal ambient temperatures. Such materials may be maintained physically separated in one or more containers which are melted or otherwise broken as a result of exposure to a temperature corresponding to a fire which initiates the transition that results from release and the mixing of the materials within the inner space 4. Mixing of the materials cause a chemical reaction and the production of a polyurethane foam within the inner space. The gas generated with the production of polyurethane foam increases the pressure within the inner space so as to deform the second wall 3 in a manner like that previously discussed. Further the filling of the inner space with polyurethane foam provides insulation properties which may improve the fire barrier function of the pressure deformed structure 8. Of course it should be understood that other types of expansion substances which provide useful properties may also be utilized in other exemplary arrangements.

[0100] FIGS. 15 and 16 show a further arrangement of a chamber element preform which is useful as a fire barrier in the protection of load bearing elements such as a load bearing column. The same reference numbers as those used to describe prior arrangements are used for similar components of the arrangement shown in FIGS. 15 and 16.

[0101] In this exemplary arrangement the chamber element preform 1 is secured to a load bearing structure such as a building column 9. The chamber element preform may be made by a manufacturing method that include steps substantially similar to those previously described. The exemplary chamber element preform shown in FIGS. 15 and 16 may not include a valve such as valve 26 or valve 28. However in other exemplary arrangements such a valve may be in fluid communication with the sealed inner space 4 of the preform so as to control deformation and the shape of the final pressure deformed structure 8.

[0102] In this exemplary arrangement the inner space 4 houses an expansion substance comprising at least two physically separated materials housed in containers, which when broken and the materials therein combine due to initiation from outside the preform, results in a transition that produces heat and vapors in a manner like that previously discussed. The exemplary preform includes an expansion substance shield 12 which in the exemplary arrangement is formed on the externally exposed second wall 3. In this exemplary arrangement the expansion substance shield 12 comprises a formed region which can accommodate and hold one or more containers which house at least one material of the expansion substance 7. In some exemplary arrangements the shield 12 may house containers for all the materials which make up the expansion substance which are maintained physically separated prior to initiation. In other exemplary arrangements the shield 12 may hold one or more materials which are maintained in physically separated containers while the remainder of the inner space contains other materials of the expansion substance. The approach depends on the particular expansion substance that is to be utilized to produce elevated pressure in the inner space as well as the chemical or physical reaction that is to be produced.

[0103] The exemplary approach of providing the shield area for housing at least some of the materials which make up the expansion substance may facilitate providing a preform with a limited initial thickness which provides for a more compact chamber preform element. Further it should be understood that while in the exemplary arrangement only a single shield area 12 is shown, in other exemplary arrangements multiple shield areas housing the same or different materials of the expansion substance may be provided.

[0104] The exemplary chamber element preform shown in FIGS. 15 and 16 includes a plurality of spaced mounting holes 11. The wall edges bounding the mounting holes are circumferentially sealed by respective suitable seals and provide for preserving the pressure tight character of the inner space 4. In the exemplary arrangement fastening elements 10 extend through the mounting holes 11 to fasten the preform to the fire protected structure. For example in exemplary arrangements the fastening elements 10 may comprise bolts which secure the preform to a load bearing column 9. In exemplary arrangements this ability to fasten the preforms to the selected areas of desired structures facilitates the ability to protect such structures against the high temperatures encountered in a fire situation.

[0105] In the exemplary arrangement the expansion substance is caused to undergo a transition of a physical and / or chemical nature due to initiation as a result of exposure to the high temperatures produced by a fire condition. In the exemplary arrangement the containers which house at least one of the materials of the expansion substance 7 is caused the melted or otherwise broken so as to cause the materials of the expansion substance to no longer be physically separated. This results in the physical and / or chemical transition of the expansion substance within the inner space 4. The transition in the exemplary arrangement produces elevated pressure in the pressure tight inner space 4 which causes deformation of the second wall 3 in the manner shown in FIGS. 15A through 15C. Such deformation results in the controlled deformation and shape of the final pressure formed structure which is operative to provide a fire barrier between the outward deformed wall surface 3 of the preform and the load bearing column 9.

[0106] Further as discussed in prior examples in certain exemplary arrangements the expansion substance may include materials which undergo transition to produce foams or other substances with insulating or fire retardant properties that are operative to protect the integrity of the pressure formed structure 8 and the protected load bearing structure to which it is attached. Numerous different suitable materials may be produced through chemical reactions and / or physical transitions of the expansion substance to protect the structure to which the preform is attached. Further in exemplary arrangements useful properties of the expansion substance may be provided upon cooling to further protect the structure in the event of subsequent exposure to fire conditions.

[0107] Thus the exemplary arrangements described herein achieve improved operations and capabilities, eliminate difficulties encountered in the use of prior arrangements, and attain useful results that are described herein.

[0108] In the foregoing description certain terms have been used for brevity, clarity and understanding. However, no unnecessary limitations are to be implied therefrom because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover the descriptions and illustrations herein are by way of examples and the new and useful features, relationships and steps are not limited to the exact features, relationships and steps that have been shown and / or described.

[0109] Having described features, discoveries and principles of the exemplary arrangements, the manner in which they are constructed, produced and operated, and the advantages and useful results attained, the new and useful features, apparatus, devices, elements, arrangements, parts, combinations, systems, equipment, operations, methods, processes and relationships are set forth in the appended claims.

Claims

1. Apparatus comprising:a chamber element preform adapted to produce a pressure formed structure includinga first wall, wherein the first wall is comprised of metal sheet and is bounded by a first wall edge,a second wall, wherein the second wall is comprised of metal sheet and is bounded by a second wall edge,wherein the first wall and the second wall are arranged so that a transverse gap extends between a respective first wall inner surface of the first wall that is in facing relation with the second wall, and a respective second wall inner surface of the second wall that is in facing relation with the first wall,a seal, wherein the seal is operative to join the first wall edge and the second wall edge in fluid tight relation,wherein a fluid tight inner space that includes the gap is bounded by the seal and extends between the first wall inner surface and the second wall inner surface,a valve, wherein the valveis in fluid connection with the inner space,is operative to cause fluid pressure that is above a set threshold pressure to escape from the inner space through the valve to outside the preform,wherein the set threshold pressure is selectively adjustable,an expansion substance, wherein the expansion substanceis housed within the inner space,is adapted to undergo physical and / or chemical transition, wherein the transitionis caused to be initiated from outside the preform,is operative to cause positive fluid pressure within the inner space sufficient to cause permanent deformation of one or more of the first wall or the second wall,wherein adjustment of the set threshold pressure is operative to control an amount of permanent deformation of one or more of the first wall or the second wall, whereby a final shape of the pressure formed structure is controlled.

2. The apparatus according to claim 1wherein the seal comprises one or more ofa fusion weld,a pressure weld,an adhesive,a crimp joint,a lap joint,a glued joint, ora pressed joint.

3. The apparatus according to claim 1wherein in transverse cross-section the first wall inner surface and the second wall inner surface are convergent so as to be closer together with increased the proximity to the seal.

4. The apparatus according to claim 1wherein the expansion substance comprises one or more ofwater,an alcohol,a mixture of two or more alcohols,glycerina chemical blowing agent,a physical blowing agent,an iron and copper (II) oxide combination, orat least two physically separated materials that are combined in the inner space as a result of the initiation to produce an increase in volume and / or the generation of heat and / or the generation of gas and / or vapor.

5. The apparatus according to claim 1wherein one of the first wall or the second wall includes a wall opening,and further includinga fluid coupling, wherein the couplingis in fixed connection with the one first wall or second wall that includes the wall opening, andis in fluid connection with the wall opening,wherein the valve is fluidly connected with the inner space through the coupling.

6. The apparatus according to claim 1wherein the valve comprises an adjustable pressure relief valve,wherein one of the first wall or the second wall includes a wall opening,and further includinga fluid coupling, wherein the couplingis in fixed connection with the one first wall or second wall that includes the wall opening, andis in fluid connection with the wall opening,wherein the valve is fluidly connected with the inner space through the coupling.

7. The apparatus according to claim 1wherein one of the first wall or the second wall includes a wall opening,and further includinga releasable fluid coupling, wherein the couplingis in fixed connection with the one first wall or second wall that includes the wall opening, andis in fluid connection with the wall opening,wherein the valveis releasably engageable with the coupling, andwhen in engagement with the coupling is fluidly connected through the coupling with the inner space.

8. The apparatus according to claim 1wherein one of the first wall or the second wall includes a wall opening,and further includesa releasable fluid coupling, wherein the couplingis in fixed connection with the one first wall or second wall that includes the wall opening,is in fluid connection with the wall opening, andis adapted to receive at least one material of the expansion substance, wherein the at least one material is delivered into the inner space through the coupling,wherein the valveis releasably engageable with the coupling, andwhen in engagement with the coupling is fluidly connected with the inner space.

9. The apparatus according to claim 1wherein one of the first wall or the second wall includes a wall opening,and further includinga fluid coupling, wherein the couplingis in fixed connection with the one first wall or second wall that includes the wall opening, andis in fluid connection with the wall opening,wherein the valveis fluidly connected with the inner space through the coupling,includes a fluid introduction port, wherein the fluid introduction port is adapted to receive at least one material of the expansion substance, wherein the fluid introduction port is in fluid connection with the wall opening, and the at least one material is enabled to be delivered into the inner space through the fluid introduction port.

10. The apparatus according to claim 1wherein one of the first wall or the second wall includes a wall opening,and further includinga fluid coupling, wherein the couplingis in fixed connection with the one first wall or second wall that includes the wall opening, andis in fluid connection with the wall opening,wherein the valveis fluidly connected with the inner space through the coupling,includes a fluid introduction port, wherein the fluid introduction port is adapted to receive at least one material of the expansion substance, wherein the fluid introduction port is in fluid connection with the wall opening,includes a check valve, wherein the check valve is operative to enable fluid flow from the fluid introduction port through the wall opening and prevent fluid flow from the wall opening to the fluid introduction port,wherein the at least one material is enabled to be delivered into the inner space through the fluid introduction port.

11. The apparatus according to claim 1wherein one of the first wall or the second wall includes a wall opening,and further includinga fluid coupling, wherein the couplingis in fixed connection with the one first wall or second wall that includes the wall opening, andis in fluid connection with the wall opening,wherein the valveis fluidly connected with the inner space through the coupling,includes a fluid introduction port, wherein the fluid introduction portis adapted to receive at least one material of the expansion substance, wherein the at least one material is enabled to be delivered into the inner space through the fluid introduction port,a removable plug, wherein the plug is adapted to close the fluid introduction port.

12. The apparatus according to claim 1wherein the transition of the expansion substance is caused to be initiated by one or more ofthe preform being exposed to a temperature above ambient temperature,the preform being exposed to another temperature below ambient temperature,vibration of the preform,a mechanical shock of the preform, ordeformation of the preform.

13. The apparatus according to claim 1wherein the valve is further operative to cause fluid pressure in the inner space that is above a fixed high pressure safety release value to escape from the inner space through the valve to outside the preform, wherein safety release value is independent of the set threshold value.

14. The apparatus according to claim 1wherein the expansion substance comprises one or more ofwater,an alcohol,a mixture of two or more alcohols,glycerina chemical blowing agent,a physical blowing agent,an iron and copper (II) oxide combination, orat least two physically separated materials that are combined in the inner space due to the initiation to produce an increase in volume and / or the generation of heat, and / or the generation of gas, and / or the generation of vapor, wherein one or more of the at least two physically separated materials prior to being combined, is held within the inner space in a respective container that is caused to be broken by the initiation.

15. The apparatus according to claim 1wherein the preform is adapted to be attached to a load bearing column,wherein the pressure formed structure is adapted to serve as a fire barrier for the load bearing column.

16. The apparatus according to claim 1and further comprising:a load bearing column,wherein the preform is in attached connection with the load bearing column, wherein the initiation is caused by preform exposure to a temperature corresponding to a fire,wherein the pressure formed structure serves as a fire barrier for the load bearing column.

17. Apparatus comprising:a chamber element preform adapted to produce a pressure formed structure, includinga first wall, wherein the first wall is comprised of metal sheet,a second wall, wherein the second wall is comprised of metal sheet,wherein the first wall and the second wall are arranged such thatthe first wall overlies the second wall, anda transverse gap extends between a first wall inner surface that is in facing relation with the second wall, and a second wall inner surface that is in facing relation with the first wall,a seal wherein the seal is operative tojoin the first wall and the second wall,bound a fluid tight inner space between the first wall inner surface and the second wall inner surface that includes the gap,a valve, wherein the valveis in fluid connection with the inner space,is operative to cause fluid pressure that is above a set threshold pressure to escape from the inner space through the valve to outside the preform,wherein the set threshold pressure is selectively adjustable,an expansion substance, wherein the expansion substanceis housed within the inner space,is adapted to undergo physical and / or chemical transition, wherein the transitionis caused to be initiated from outside the preform,is operative to cause positive fluid pressure within the inner space sufficient to permanently deform one or more of the first wall or the second wall,wherein adjustment of the set threshold pressure is operative to control an amount of permanent deformation of one or more of the first wall or the second wall, whereby a final shape of the pressure formed structure is controlled responsive to the set threshold pressure.

18. The apparatus according to claim 17wherein the first wall is bounded by a first wall edge,wherein the second wall is bounded by a second wall edge,wherein the seal is continuous and is operative to engage the first wall edge and the second wall edge in sealed fluid tight relation.

19. The apparatus according to claim 18wherein one of the first wall or the second wall includes a wall opening,and further includinga fluid coupling, wherein the couplingis in fixed connection with the one first wall or second wall that includes the wall opening, andis in fluid connection with the wall opening,wherein the valveis releasably engageable with the fluid coupling, andis fluidly connected with the inner space through the coupling,wherein the coupling is adapted to enable at least one material of the expansion substance to be delivered into the inner space when the valve is disengaged from the coupling.

20. A method comprising:making a chamber element preform that is adapted to produce a pressure formed structure, by performing steps including:a) providing a first wall comprised of metal sheet and that is bounded by a first wall edge,b) providing a second wall comprised of metal sheet and that is bounded by a second wall edge,c) arranging the first wall and the second wall so that a transverse gap extends between a respective first wall inner surface of the first wall that is in facing relation with the second wall, and a respective second wall inner surface of the second wall that is in facing relation with the first wall,d) joining the first wall edge and the second wall edge in fluid tight relation with a seal such that a fluid tight inner space that includes the gap is bounded by the seal and extends between the first wall inner surface and the second wall inner surface,e) providing a valve, wherein the valveis in fluid connection with the inner space,is operative to cause fluid pressure that is above a set threshold pressure to escape from the inner space through the valve to outside the preform, wherein the set threshold pressure is selectively adjustable,f) providing an expansion substance housed within the inner space, wherein the expansion substanceis adapted to undergo physical and / or chemical transition, wherein the transitionis caused to be initiated from outside the preform,is operative to cause positive fluid pressure within the inner space sufficient to permanently deform one or more of the first wall or the second wall,whereby adjustment of the set threshold pressure of the valve is operative to control an amount of permanent deformation of one or more of the first wall or the second wall, whereby a final shape of the pressure formed structure is controlled by the set pressure.

Images