Method for constructing structure

Abstract

In a method for constructing a structure in which a foam material is provided on the inner side of an outer skin member, pressure is applied with air from a blower through an inlet portion provided in the outer skin member (20), the outer skin member (20) is kept expanded by 70% to 80%, a holding member for holding the outer skin member (20) so as not to move with respect to an installation surface is placed on the inner side or outer side of the outer skin member (20), and additional air is blown so that the outer skin member (20) expands by a predetermined amount more than 100%.

Description

Construction method of the structure CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is based on and claims the benefit of priority from Japanese Patent Application No. 2024-001135, filed on January 9, 2024, the entire contents of which are incorporated herein by reference.

[0002] The present disclosure relates to a construction method for a structure.

[0003] Structures with interior spaces are widely used in fields such as tents and temporary housing. Such structures are required to have a certain level of strength and durability to withstand both indoor and outdoor use. Various methods for increasing the strength and durability of structures have been studied. For example, Patent Document 1 discloses a structure including a thin film and a gas-entrained material. This structure is said to have strength and durability, and the shape of the structure is stable. In Patent Document 1, a foamed resin (foam material) is used as the gas-entrained material, and the thin film and the gas-entrained material are integrated by spraying the foamed resin onto the thin film.

[0004] Japanese Patent Application Laid-Open No. 2018-168606

[0005] In Patent Document 1, when constructing a structure, the thin film is inflated from the inside with pressurized gas, and then a gas-mixed material is sprayed onto the inside of the thin film to fix it, but no more specific construction method is disclosed.

[0006] The present disclosure specifically presents a construction method for a structure in which a foam material is provided inside an outer skin member.

[0007] The present disclosure relates to a construction method for a structure in which a foam material is provided inside an outer skin member, and includes an outer skin holding process in which a blower applies pressure to the interior of the outer skin member through an inlet portion provided in the outer skin member, maintaining the outer skin member so that it expands by 70 to 80 percent, and also places a holding member on the inside or outside of the outer skin member to hold the outer skin member so that it does not move relative to the installation surface, and an additional air blowing process in which, after the placement of the holding member has been completed, additional air is blown so that the outer skin member expands by a predetermined amount more than 100 percent.

[0008] Fig. 1 is an external view showing an example of a structure formed by the construction method according to this embodiment. Fig. 2 is a diagram for explaining the construction method according to this embodiment. Fig. 3 is a diagram for explaining the construction method according to this embodiment. Figs. 4(A), 4(B), and 4(C) are diagrams for explaining the construction method according to this embodiment. Figs. 5(A) and 5(B) are diagrams for explaining the construction method according to this embodiment. Fig. 6 is a diagram for explaining the construction method according to this embodiment.

[0009] Hereinafter, the present embodiment will be described with reference to the accompanying drawings. To facilitate understanding of the description, the same components in the drawings will be denoted by the same reference numerals as much as possible, and duplicated descriptions will be omitted.

[0010] Fig. 1 shows an example of a structure formed by the construction method according to this embodiment. The structure 2 shown in Fig. 1 comprises a cylindrical portion 22 and a conical portion 23. The conical portion 23 is connected to the top of the cylindrical portion 22, and the cylindrical portion 22 and the conical portion 23 are provided integrally. The cylindrical portion 22 is provided with an inlet 31 and a window 32.

[0011] The construction method according to this embodiment will be described with reference to Figures 2 to 6. This construction method will be described assuming that the structure 2 described with reference to Figure 1 is constructed.

[0012] As shown in Fig. 2, an installation member 10, an outer skin member 20, and a blower 11 are prepared. The installation member 10 is a member for installing the structure 2, and is, for example, a wood deck, the ground, a concrete floor, or asphalt. The blower 11 has a pressurizing capacity capable of sending air into the outer skin member 20 and completely inflating the outer skin member 20.

[0013] The outer skin member 20 is a thin film member that forms the outer skin of the structure 2. The outer skin member 20 may have a laminated structure. Multiple members may be bonded together with an adhesive. There are no other limitations on the material of the outer skin member 20 as long as it can be stretched even slightly when pulled, and any material that will not break when performing the construction method described below should be used. The outer skin member 20 is preferably made of a material that will not break or otherwise be damaged by the pressure of gas when gas is introduced into the interior of the outer skin member 20.

[0014] Examples of the outer cover member 20 include a resin substrate (which may be a resin film or a resin sheet), a paper substrate, and a leather substrate. The outer cover member 20 may be made of other materials. Examples of the resin substrate include acrylic, polyolefin, polyester, nylon, polyethylene, and polyvinyl chloride. Examples of polyolefin include polypropylene. Examples of polyester include polyethylene terephthalate. An example of the resin substrate contains an ultraviolet absorber. Examples of the paper substrate include high-quality paper, Japanese paper, Western paper, synthetic paper, and nonwoven fabric.

[0015] As an example, the outer cover member 20 is water-resistant. As an example, the outer surface of the outer cover member 20 is water-resistant. Examples of the water-resistant outer cover member 20 include polyester, acrylic resin, and polyvinyl chloride.

[0016] As an example, the outer cover member 20 has water repellency. As an example, the outer surface of the outer cover member 20 has water repellency. Examples of the outer cover member 20 having water repellency include fluororesin and silicone.

[0017] As an example, the outer cover member 20 is water-resistant and water-repellent. As an example, the outer cover member 20 has a single-layer structure that is water-resistant and water-repellent. As an example, the outer cover member 20 has a layered structure in which a water-resistant member and a water-repellent member are layered.

[0018] As an example, the outer cover member 20 has been subjected to an adhesive treatment on the inner surface thereof. Examples of adhesive treatments include corona discharge treatment, flame treatment, ozone treatment, ultraviolet treatment, radiation treatment, surface roughening treatment, chemical treatment, plasma treatment, and grafting treatment. This type of outer cover member has good adhesion to the foam material.

[0019] Fig. 3 is a plan view seen from direction A in Fig. 2. As shown in Fig. 2, a fixing portion 20E is provided in an annular shape around the outer cover member 20. Fixing points 201, 202, 203, 204, 205, 206, 207, 208, 209, 210, 211, and 212 for fixing the outer cover member 20 to the installation member 10 are provided at equal intervals on the fixing portion 20E.

[0020] When fixed portion 20E is likened to the face of a clock, fixed point 212 is located at the 12 o'clock position. Similarly, fixed point 201 is located at the 1 o'clock position, fixed point 202 at the 2 o'clock position, fixed point 203 at the 3 o'clock position, fixed point 204 at the 4 o'clock position, fixed point 205 at the 5 o'clock position, fixed point 206 at the 6 o'clock position, fixed point 207 at the 7 o'clock position, fixed point 208 at the 8 o'clock position, fixed point 209 at the 9 o'clock position, fixed point 210 at the 10 o'clock position, and fixed point 211 at the 11 o'clock position.

[0021] The fixed point 206 is provided at a position corresponding to the entrance 31 of the structure 2. Therefore, the above positional relationship can also be considered as a positional relationship when the fixed point 206 provided at a position corresponding to the entrance 31 of the structure 2 is at the 6 o'clock position on the face of a clock.

[0022] The inside of the outer cover member 20 is pressurized with air from an inlet provided in the outer cover member 20 by a blower 11, the outer cover member 20 is kept expanded by 70 to 80 percent, and screws are driven into fixing points 206 provided in the inlet portion to fix the outer cover member 20 to the installation member 10.

[0023] Next, while pulling the outer cover member 20 outward, a screw is driven into the fixing point 212 on the opposite side on the line connecting the fixing point 206 and the center of the outer cover member 20, and the outer cover member 20 is fixed to the installation member 10.

[0024] Next, while pulling the outer cover member 20 outward, screws are driven into fixing points 203 and 209 to fix it to the installation member 10. Similarly, while pulling the outer cover member 20 outward, screws are driven into fixing points 204 and 210 to fix it to the installation member 10. Similarly, while pulling the outer cover member 20 outward, screws are driven into fixing points 201 and 207 to fix it to the installation member 10. Similarly, while pulling the outer cover member 20 outward, screws are driven into fixing points 205 and 211 to fix it to the installation member 10. Similarly, while pulling the outer cover member 20 outward, screws are driven into fixing points 202 and 208 to fix it to the installation member 10. After fixing of fixing points 201 to 212 is completed, screws are driven into fixing points between fixing points 201 to 212 to fix it to the installation member 10.

[0025] If the installation member 10 is made of concrete or asphalt, where it is difficult or impossible to drive screws into, a weight may be placed inside the outer skin member 20 to prevent it from moving relative to the installation member 10. For example, a method can be used in which a holding plate having an outer skin holding portion along the outer periphery of the outer skin member 20 is placed inside the outer skin member 20, and a weight is placed on the holding plate.

[0026] Next, the output of the blower 11 is increased to blow additional air so that the outer cover member 20 expands by a predetermined amount more than 100%. "Inflating the outer cover member 20 by a predetermined amount more than 100%" means that 1 to 2% of the indoor air pressure required for the outer cover member 20 to expand by 100% is added to the indoor air pressure required for the outer cover member 20 to expand by 100%. More specifically, "inflating the outer cover member 20 by a predetermined amount more than 100%" means that the indoor air pressure is 20 hPa±5 hPa higher than the outside air pressure, for example. At this stage, it is confirmed that the outer cover member 20 does not lift off the installation member 10.

[0027] Next, as an example, a flooring material (not shown) with thermal insulation properties is laid inside the room covered by the outer skin member 20. The flooring material is pre-cut to fit the shape of the room covered by the outer skin member 20 minus the thickness of the sprayed insulation material. The laid flooring material is then covered with a protective material and cured. Next, a shading sheet is placed over the outer skin member 20 to prevent the internal temperature from rising due to sunlight.

[0028] Next, as an example, as shown in Fig. 4(A), measuring rods 15 are installed inside the outer cover member 20 at an installation density of approximately one per 2 square meters. The measuring rods 15 have a flat plate portion 151 and a needle portion 152. The measuring rods 15 are fixed by attaching the flat plate portion 151 to the outer cover member 20 with double-sided tape or the like.

[0029] 5 shows the installation position of the measuring rod 15 in a lower outer skin member 20L, which is a part of the outer skin member 20 and corresponds to the cylindrical portion 22. Fig. 5(A) is a plan view of the lower outer skin member 20L, and Fig. 5(B) is a perspective view of the lower outer skin member 20L.

[0030] As shown in Figures 5(A) and 5(B), the measuring rods 15 are installed at measuring points P1, P2, P3, P4, P5, and P6.

[0031] 6 shows the installation positions of the measuring rods 15 in an upper skin member 20U that is a part of the skin member 20 and corresponds to the conical portion 23. As shown in FIG. 6, the measuring rods 15 are installed at measurement points P11, P12, P13, and P14.

[0032] The explanation will be continued with reference to Figure 4. After the measuring rod 15 is set in a predetermined position as shown in Figure 4(A), the foam material is attached to the inside of the outer skin member 20. During this work, it is preferable that the worker wears work clothes with a water-cooling function. It is also preferable that the worker wears protective clothing and a protective cover.

[0033] 4(B), a foam material is applied to a position where the measuring rod 15 is partially or entirely hidden, thereby forming a layer of the first foam material 41. The layer of the first foam material 41 has a thickness of, for example, about 10 mm. When forming the layer of the first foam material 41, it is preferable to apply the foam material thinly and in patches several times.

[0034] 4(C), the foam material is applied to a position where the entire measuring rod 15 is hidden, thereby forming a layer of the second foam material 42. The layer of the second foam material 42 has a thickness of, for example, about 40 mm. When forming the layer of the second foam material 42, it is preferable to apply the foam material in two steps of 20 mm each.

[0035] The foaming material may be any material that can be foamed at a predetermined expansion ratio, and any conventionally known foaming material may be appropriately selected and used. The foaming material foams and hardens after application. Examples of foaming materials include acrylic, polyurethane, polystyrene, phenol, polyvinyl chloride, polyolefin, urea resin, urethane-urea resin, silicone, polyimide, melamine, glass, ceramics, soil, and explosive ingredients. Other foaming materials may also be used.

[0036] The expansion ratio of the foam material is not limited. For example, the expansion ratio of the foam material is 10 to 100 times, preferably 30 to 50 times. The foam material preferably has a linear expansion coefficient higher than that of the outer cover member 20. The foam material preferably foams by generating or absorbing heat after application. The foam material may contain other components such as a liquid solvent, a gaseous solvent, and a functional material.

[0037] The foaming material is applied by bringing a foaming device (not shown) into the interior space of the outer cover member 20 and having an operator spray the foaming material onto the inner surface of the outer cover member 20. An example of the foaming device has a hose or a nozzle capable of spraying the foaming material. An example of the foaming device is a spray gun. When the foaming material is applied by application, any conventionally known application means can be appropriately selected and used.

[0038] When spraying the foaming material, for example, the temperature of the foaming device is set to about 40°C and adjusted to 38°C at the nozzle tip. The spray pressure is 4 kg / cm ２ is the basic setting.

[0039] After the foam material application described above is completed, a mesh material may be attached inside and the foam material application described above may be repeated once again, so that the total thickness of the foam material becomes, for example, 100 mm.

[0040] Next, an opening such as a window 32 is provided in the structure 2. When applying the foam material, the opening is covered with masking tape to prevent the foam material from being applied. The foam material is maintained at a specified thickness (50 mm or 100 mm) up to 10 mm outside the curing position.

[0041] As an example of how the opening is treated, the outer skin member 20 is cut along the guide line of the opening, and the outer skin member 20 is folded back toward the interior and secured with a stapler or the like. A foam material is attached to cover the secured portion of the outer skin member 20 folded back toward the interior, forming a foam layer. A window part may be attached to the opening corresponding to the window 32.

[0042] [Notes] Notes 1 to 6 below can be combined in any way as long as there is no technical contradiction.

[0043] [Appendix 1] A construction method for a structure in which foam materials 41, 42 are provided inside an outer skin member 20, the construction method for a structure including: an outer skin holding step of applying internal pressure with air by a blower 11 through an inlet portion provided in the outer skin member 20 to maintain the outer skin member 20 expanded by 70 to 80 percent, and placing a holding member on the inside or outside of the outer skin member 20 to hold the outer skin member 20 so as to prevent it from moving relative to the installation surface; and an additional air blowing step of blowing additional air so that the outer skin member 20 expands by a predetermined amount more than 100 percent after the placement of the holding member has been completed.

[0044] [Appendix 2] The skin holding process is a construction method for a structure described in Appendix 1, which includes: a first fixing process in which the skin member 20 is kept expanded by 70 to 80 percent, and a first fixing point (fixing point 206) provided at the entrance portion is fixed to the installation surface with a holding member; a second fixing process in which, while pulling the skin member 20 outward, a second fixing point (fixing point 212) on the opposite side of the line connecting the first fixing point and the center of the skin member 20 is fixed to the installation surface with a holding member; a third fixing process in which, while pulling the skin member 20 outward, a third fixing point (fixing point 203) located between the first fixing point and the second fixing point and a fourth fixing point (fixing point 209) on the opposite side of the line connecting the third fixing point and the center of the skin member 20 are fixed to the installation surface with holding members; and a fourth fixing process in which all other fixing points are fixed to the installation surface with holding members.

[0045] In this embodiment, the first fixing point 206 is located at the 6 o'clock position, the second fixing point 212 is located at the 12 o'clock position, the third fixing point 203 is located at the 3 o'clock position, and the fourth fixing point 209 is located at the 9 o'clock position, but these are merely examples and the positions of the fixing points are not limited to these. Also, in this embodiment, screws are used as an example of holding members, but other fixing means can be used as long as they can fix the fixing points to the installation surface.

[0046] [Appendix 3] The construction method for a structure described in Appendix 1, wherein the outer skin holding step includes an internal holding step of placing a holding plate having an outer skin holding portion along the outer periphery of the outer skin member 20 inside the outer skin member 20 and placing a weight on the holding plate.

[0047] In Supplementary Note 3, it is preferable that the holding plate has a thickness that does not interfere with the spraying of the foam materials 41, 42 onto the inside of the outer skin member 20. It is preferable that the weight placed on the holding plate is placed not on the periphery of the holding plate but toward the center so as not to interfere with the spraying of the foam materials 41, 42 onto the inside of the outer skin member 20.

[0048] [Appendix 4] A construction method for a structure according to any one of Appendices 1 to 3, including, following the skin holding step, a measuring rod installation step of installing a measuring rod 15 on the inside of the skin member 20 to measure the thickness of the foam materials 41, 42, and a foam material attachment step of attaching a foam material to become the foam materials 41, 42 to the inside of the skin member 20 so that the measuring rod 15 is buried.

[0049] [Appendix 5] The method for constructing a structure according to Appendix 4, wherein the foam material application step is carried out by a worker wearing work clothing having a water-cooling function that circulates water to lower the wearer's perceived temperature.

[0050] [Appendix 6] A construction method for a structure according to Appendix 4 or 5, including an opening processing step of preventing the formation of foam material at a position corresponding to an opening in the structure 2 before the foam material attaching step, and processing the outer skin member 20 to form an opening in the structure 2 after the foam material attaching step, and providing the foam material in the processed portion of the outer skin member 20.

[0051] The present embodiment has been described above with reference to specific examples. However, the present disclosure is not limited to these specific examples. Design modifications to these specific examples made by a person skilled in the art as appropriate are also included within the scope of the present disclosure as long as they comprise the features of the present disclosure. The elements of the above-described specific examples, as well as their arrangement, conditions, shape, etc., are not limited to those exemplified and can be modified as appropriate. The elements of the above-described specific examples can be combined in various ways as appropriate, as long as no technical contradictions arise.

Claims

1. A construction method for a structure in which a foam material is provided inside an outer skin member, comprising: a pressurizing step of pressurizing the inside with air by a blower from an inlet portion provided in the outer skin member and maintaining the outer skin member so as to expand by 70% to 80%, and an outer skin holding step of disposing a holding member for holding the outer skin member so as not to move with respect to the installation surface inside or outside the outer skin member; and an additional blowing step of performing additional blowing so that the outer skin member expands by a predetermined amount more than 100% after the arrangement of the holding member is completed.

2. The construction method of the structure according to claim 1, wherein the outer skin holding step includes: a first fixing step of maintaining the outer skin member so as to expand by 70% to 80% and fixing a first fixing point provided at the inlet portion to the installation surface by the holding member; a second fixing step of fixing a second fixing point on the opposite side on the line connecting the first fixing point and the center of the outer skin member to the installation surface by the holding member while pulling the outer skin member outward; a third fixing step of fixing a third fixing point located between the first fixing point and the second fixing point and a fourth fixing point on the opposite side on the line connecting the third fixing point and the center of the outer skin member to the installation surface by the holding member while pulling the outer skin member outward; and a fourth fixing step of fixing all other fixing points to the installation surface by the holding member.

3. The construction method of the structure according to claim 1, wherein the outer skin holding step includes an internal holding step of disposing a holding plate having an outer skin holding portion along the outer periphery of the outer skin member inside the outer skin member and placing weights on the holding plate.

4. The construction method of the structure according to any one of claims 1 to 3, further including a measuring rod installation step of installing a measuring rod for measuring the thickness of the foam material inside the outer skin member following the outer skin holding step; and a foam material adhesion step of adhering a foam material to be the foam material inside the outer skin member so that the measuring rod is buried.

5. The construction method of the structure according to claim 4, wherein the foam material adhesion step is performed by an operator wearing a work suit having a water cooling function of reducing the body temperature of the wearer by circulating water.

6. A method for constructing the structure according to claim 4, comprising: before the foam material attaching step, preventing the formation of the foam material at a position corresponding to the opening of the structure; after the foam material attaching step, processing the outer skin member to provide an opening in the structure, and providing the foam material at a portion where the outer skin member is processed, the opening processing step.

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