An apparatus and method for forming a wall of a hollow structure for use in a space environment

Abstract

The present disclosure relates to an apparatus for forming a wall of a hollow structure for use in a space environment. The apparatus comprises a supply mechanism and a wall forming mechanism. The supply mechanism is configured to receive a supply of sheet material. The wall forming mechanism is configured such that, in use, sheet material is fed from the supply mechanism to the wall forming mechanism. The wall forming mechanism comprises one or more guide members configured to guide the sheet material to advance about a conveyance axis and in an axial direction along the conveyance axis to form a wall of a hollow structure. According to the present disclosure, there is also provided a method of forming a wall of a hollow structure for use in a space environment, and a method and apparatus for forming a hollow structure for use in a space environment.

Description

[0001] An apparatus and method for forming a wall of a hollow structure for use in a space environment

[0002] Technical Field The present disclosure relates to an apparatus forming a wall of a hollow structure for use in a space environment. The present disclosure also relates to a method of forming a wall of a hollow structure for use in a space environment, to an assembly apparatus, and a sheet material. The present disclosure also relates to a method and apparatus for forming a hollow structure.

[0003] Background

[0004] Placing spacecraft or components thereof into space is a complex task in which an increase in the size of the spacecraft / components to be placed into space can dramatically increase the cost of the operation. The spacecraft / components must fit within given dimensions of the launch vehicle. This is particularly challenging for spacecraft with large dimensions or which require, for example, large components such as large solar arrays or antennae that must fit within the payload volume of the launch vehicle. Summary

[0005] It is an object of the present invention to provide an apparatus and method for forming a wall of a hollow structure for use in a space environment.

[0006] In accordance with embodiments of the invention described herein, there is provided an apparatus for forming a wall of a hollow structure for use in a space environment, the apparatus comprising: a supply mechanism configured to receive a supply of sheet material; and, a wall forming mechanism configured such that, in use, sheet material is fed from the supply mechanism to the wall forming mechanism, the wall forming mechanism comprising one or more guide members configured to guide the sheet material to advance about a conveyance axis and in an axial direction along the conveyance axis to form a wall of a hollow structure.

[0007] Advantageously, the supply of sheet material can be transported to the space environment and then a larger wall of the hollow structure can be formed from the supply. The supply may occupy a smaller volume than the wall and therefore is easier and less expensive to transport. In addition, it has been found that forming the wall in the manner described above provides high torsional stiffness of the hollow structure. Furthermore, the apparatus may optionally be used to form multiple walls from a single supply of sheet material and / or by replenishing the supply of sheet material. The apparatus can form the wall of the hollow structure relatively quickly and is also relatively cost-effective to operate.

[0008] In some embodiments, the one or more guide members are configured to guide the sheet material to advance about the conveyance axis and in the axial direction along the conveyance axis such that the hollow structure advances in the axial direction.

[0009] The hollow structure may be a habitable structure. The apparatus may be an apparatus for forming a wall of a habitable structure for use in a space environment. In some embodiments, the hollow structure is for human habitation.

[0010] The hollow structure may comprise an enclosed chamber that protects occupants of the enclosed chamber from the space environment. The enclosed chamber may be hermetically sealed. The wall may form at least part of a boundary of the enclosed chamber.

[0011] In some embodiments, the sheet material of the wall forms a hermetic seal that prevents the egress of air from exiting the enclosed chamber. Alternatively, or additionally, the hollow structure may comprise a layer of material that seals the enclosed chamber (or provides an additional seal). In some embodiments, the layer of material is provided to the hollow structure after the wall(s) of the hollow structure have been constructed. In other embodiments, the layer of material is incorporated whilst the wall(s) are being constructed. In some embodiments, the apparatus comprises a layer provision mechanism that is configured to provide a layer of material. The layer of material forms part of the wall of the hollow structure. In some embodiments, the layer provision mechanism is configured to provide the layer of material on the interior or exterior of the wall. In some embodiments, the layer of material is at least one of: a sealing layer, a thermally insulating layer, and / or a shielding layer. In some embodiments, the sealing layer is configured to hermetically seal the wall. In some embodiments, the shielding layer is configured to shield the interior of the hollow structure from radiation, for example, ionising radiation.

[0012] In some embodiments, the layer of material is an inner layer of the wall.

[0013] The layer of material may be a multi-layer insulation, for example, a multi-layer thermal insulation.

[0014] In some embodiments, the layer of material is a spayed layer and, optionally, the sprayed layer is applied to an interior or exterior surface of the wall.

[0015] In some embodiments, the layer of material comprises a flexible material.

[0016] In some embodiments, the layer of material comprises a bladder and, preferably, wherein the bladder is inflatable. The bladder may be a flexible bag of material.

[0017] In some embodiments, the bladder comprises one or more sealable or resealable openings to allow objects and / or people to enter or exit the bladder.

[0018] The opening may comprise an airlock. In some embodiments, the airlock is premanufactured and attached to the bladder. The airlock may be part of a panel that is attached to the bladder to provide a means of entering / exiting the bladder.

[0019] An open end of the bladder may be sealed about an access of the hollow structure, for example, an airlock.

[0020] In some embodiments, the apparatus is configured to receive a supply of a second sheet material, wherein the structure forming mechanism is configured such that, in use, the second sheet material is fed to the structure forming mechanism, and wherein the one or more guide members is configured to guide the second sheet material to advance about the conveyance axis and in the axial direction to form an additional layer of the wall of the hollow structure. In some embodiments, the apparatus further comprises a second supply mechanism configured to receive the supply of the second sheet material, wherein the structure forming mechanism is configured such that, in use, the second sheet material is fed from the second supply mechanism to the structure forming mechanism, and wherein the one or more guide members is configured to guide the second sheet material to advance about the conveyance axis and in the axial direction to form an additional layer of the wall of the hollow structure.

[0021] In other embodiments, the supply mechanism is configured to receive both the supply of sheet material and the second supply of sheet material. In some embodiments, the supply and second supply of sheet material are received on a single bobbin of the supply mechanism.

[0022] In some embodiments, the sheet material is one of an interior or exterior sheet material.

[0023] In some embodiments, the second sheet material is one of an interior or exterior sheet material. In some embodiments, the sheet material is the other one of the interior or exterior sheet material.

[0024] In some embodiments, the layer of material provided by the layer provision mechanism is located between the sheet material and the second sheet material of the wall of the hollow structure. In some embodiments, the layer of material separates the sheet material from the second sheet material.

[0025] In some embodiments, the wall is a tube and, preferably, is substantially cylindrical.

[0026] In some embodiments, the sheet material has first and second edges, and wherein the one or more guide members are configured to guide the sheet material to advance about the conveyance axis and in the axial direction such that the first edge overlaps the second edge.

[0027] In some embodiments, the overlap of the first and second edges is at least 1% of the width of the sheet material and, preferably, is at least 2%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45% or 50% of the width of the sheet material. In some embodiments, the overlap of the first and second edges is at most 50% of the width of the sheet material and, preferably, is at most 40 %, 30 % or 25 % or 20% of the width of the sheet material. In some embodiments, the one or more guide members are configured to guide the sheet material along a substantially helical path.

[0028] In some embodiments, the apparatus comprises a joining mechanism that is configured to join a first portion of the sheet material to a second portion of the sheet material and, preferably, wherein the joining mechanism comprises a heater configured to heat the sheet material.

[0029] In some embodiment, the heater is configured to inductively heat the sheet material. In some embodiments, the joining mechanism is configured to join the first and second portions such that the sheet material is retained in the form of the wall of the hollow structure.

[0030] In some embodiments, the heater is configured to melt at least one of the first and second portions of the sheet material such that said portion subsequently cools and solidifies to join the first and second portions of the sheet material. Advantageously, the portions can therefore be joined together without providing an additional adhesive, thereby simplifying the manufacturing process of the wall of the hollow structure. In some embodiments, the apparatus is configured such that, in use, the first and second portions of sheet material are pressed together. This may help to join the first and second portions.

[0031] In some embodiments, the joining mechanism is configured to join the first and second portions after the sheet material has been guided by the one or more guide members.

[0032] In some embodiments, the first and second portions of the sheet material are pressed together by a pair of rollers and, preferably, by first and second guide rollers. In some embodiments, the joining mechanism is configured such that the join of the first and second portions subtends continuously about the conveyance axis to form a hermetic seal. In some embodiments, the or each guide member is moveable to accommodate movement of the sheet material. In some embodiments, the or each guide member is a roller or belt.

[0033] In some embodiments, the or at least one of the guide members comprises a guide roller. In some embodiments, the guide members comprise at least one pair of guide rollers configured such that the sheet material passes between the guide rollers. The pair of rollers may be configured to impart a curvature of motion to the sheet material.

[0034] In one embodiment, one of the guide rollers of the pair has a larger diameter than the other one of the guide rollers of the pair. The pair of guide rollers may be configured to form an English wheel.

[0035] In some embodiments, the or at least one of the guide members is adjustable to adjust the size of the wall of the hollow structure that is formed by the apparatus.

[0036] In some embodiments, the diameter of the wall of the habitable structure may be gradually decreased as the wall is formed.

[0037] In some embodiments, the diameter of the wall of the habitable structure may be gradually decreased as the wall is formed such that the wall of the habitable structure has a cone or dome shape or a truncated cone or dome shape.

[0038] The apparatus may comprise at least one arm, and wherein at least one of the guide members is configured to be moved along the arm to adjust the size of the wall of the hollow structure.

[0039] In some embodiments, the position of the or at least one of the guide members relative to the conveyance axis is adjustable to adjust the size of the wall of the hollow structure. In some embodiments, the or at least one of the guide members is adjustable to adjust a radius that the sheet material is advanced about the conveyance axis to adjust the diameter of the wall of the hollow structure. In some embodiments, the apparatus comprises a cutting device that is configured to a separate the wall of the hollow structure from the sheet material received in the supply mechanism.

[0040] In some embodiments, the width of the wall of the hollow structure is at least 2 metres and, preferably, at least 3, 5, 10, 15, 20, 30, 40 or 50 metres. In some embodiments, the width of the hollow structure is the diameter of the hollow structure. Thus, the diameter of the wall of the hollow structure may be at least 2 metres and, preferably, at least 3, 5, 10, 15, 20, 30, 40 or 50 metres. In some embodiments, the apparatus comprises a supply of sheet material received in the supply mechanism.

[0041] In some embodiments, the sheet material comprises a composite material. In some embodiments, the sheet material comprises carbon fibre reinforced thermoplastic.

[0042] In some embodiments, the supply mechanism is configured to receive a roll of sheet material.

[0043] In some embodiments, the supply mechanism comprises a roll holder. In some embodiments, the roll holder comprises a bobbin for receiving the roll of sheet material.

[0044] In some embodiments, the apparatus comprises a drive that, in use, is operable to urge the sheet material to be fed from the supply mechanism to the structure forming mechanism and, preferably, the drive comprises a motor.

[0045] In some embodiments, the drive comprises a pair of opposing drive members configured to receive the sheet material therebetween, and wherein, in use, the drive is operable to rotate at least one of the drive members to urge the sheet material to be fed from the supply mechanism to the structure forming mechanism. In some embodiments, the drive members are rollers. In one such embodiment, the motor is operable to urge one or both of the drive rollers to rotate to urge the sheet material to be fed from the supply mechanism to the structure forming mechanism. In other embodiments, the drive is operable to rotate at least one of the guide members to urge the sheet material to be fed from the supply mechanism to the structure forming mechanism.

[0046] In yet further embodiments, the drive is operable to rotate one or more components of the supply mechanism to urge the sheet material to be fed from the supply mechanism to the structure forming mechanism. For example, the supply mechanism may comprise a roll holder (for example, a bobbin) that receives a roll of the sheet material, and wherein the drive is operable to rotate the roll holder to urge the sheet material to be fed from the supply mechanism to the structure forming mechanism.

[0047] In some embodiments, in use, the drive is operable to increase an axial length of the wall of the hollow structure. The axial length of the wall of the hollow structure may be adjustable. In some embodiments, in use, the drive is operable to urge the sheet material to be fed from the structure forming mechanism to the supply mechanism to reduce an axial length of the elongate member. Advantageously, in some embodiments the sheet material may be recycled. In some embodiments, the sheet material comprises one or more susceptors.

[0048] The apparatus may be configured to operate in the space environment to form the wall of the hollow structure. According to the present disclosure, there is also provided an apparatus for forming a hollow space structure, the apparatus comprising: an apparatus for forming a wall of a hollow structure according to the present disclosure; and, a device for enclosing an end of the wall. In some embodiments, the device is configured to provide an end wall at the end of the wall of the hollow structure. The device may comprise, for example, a robotic arm. In some embodiments, the device is configured to attach the end wall to the wall of the hollow structure.

[0049] According to the present disclosure, there is also provided a method of forming a wall of a hollow structure for use in a space environment, the method comprising: feeding sheet material from a supply of sheet material and guiding the sheet material to advance about a conveyance axis and in an axial direction along the conveyance axis to form the wall of the hollow structure. In some embodiments, the method comprises: feeding sheet material from a supply of sheet material to one or more guide members; and, using the one or more guide members to guide the sheet material to advance about a conveyance axis and in an axial direction along the conveyance axis to form the wall of the hollow structure. In some embodiments, at least part of the method is performed in the space environment. The method may further comprise the step of transporting the supply of sheet material to the space environment.

[0050] According to the present disclosure, there is also provided a wall of a hollow structure formed by the above method.

[0051] According to the present disclosure, there is also provided a method of forming a hollow structure for a space environment, the method comprising providing an enclosed hollow chamber that is surrounded by a wall, wherein the wall is formed according to the method of the present disclosure. An end of the wall may be enclosed.

[0052] The method of forming the hollow structure may comprise enclosing an end of the wall.

[0053] The method may comprise enclosing opposite ends of the wall. The method may comprise enclosing one or both end walls with sheet material. In some embodiments, the method is performed in the space environment.

[0054] In some embodiments, the method comprises forming the wall of the hollow structure and then enclosing one or both ends of the wall. In another embodiment, an end wall may be attached to the sheet material (or a partially formed wall which may comprise a loop of sheet material), and then the sheet material may be guided to advance about the conveyance axis and in the axial direction along the conveyance axis to form the wall of the hollow structure that is closed at one end by the end wall attached thereto. According to the present disclosure, there is also provided a hollow structure formed by the above method. According to the present disclosure, there is also provided an apparatus configured to operate in a space environment to form a wall of a hollow structure, the apparatus comprising: a supply mechanism configured to receive a supply of sheet material; and, a wall forming mechanism configured such that, in use, sheet material is fed from the supply mechanism to the wall forming mechanism, the wall forming mechanism comprising one or more guide members configured to guide the sheet material to advance about a conveyance axis and in an axial direction along the conveyance axis to form a wall of a hollow structure. The apparatus may comprise any of the features described herein. According to the present disclosure, there is also provided a spacecraft comprising an apparatus for forming a wall of a hollow structure, the apparatus comprising: a supply mechanism configured to receive a supply of sheet material; and, a wall forming mechanism configured such that, in use, sheet material is fed from the supply mechanism to the wall forming mechanism, the wall forming mechanism comprising one or more guide members configured to guide the sheet material to advance about a conveyance axis and in an axial direction along the conveyance axis to form a wall of a hollow structure. The apparatus may comprise any of the features described herein.

[0055] Brief Description of the Drawings Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0056] Fig. 1 is a side view of an embodiment of an apparatus for forming a wall of a hollow structure; Fig. 2 is a perspective view of the apparatus of Fig. 1;

[0057] Fig. 3 is a side view of the apparatus of Fig. 1, configured to form a wall with a first diameter;

[0058] Fig. 4 is a side view of the apparatus of Fig. 1, configured to form a wall with a second diameter; Fig. 5 is a perspective view of roll of sheet material for the apparatus of Fig. 1; Fig. 6 is a wall formed by the apparatus of Fig. 1, wherein the wall is attached to a supply of sheet material;

[0059] Fig. 7 is a wall formed by the apparatus of Fig 1, wherein the wall has been separated from the supply of sheet material; Fig. 8 is a schematic block diagram illustrating an adjustment system of the apparatus of Fig. 1;

[0060] Fig. 9 is a side view of another embodiment of an apparatus for forming a wall of a hollow structure;

[0061] Fig. io is a side view of another embodiment of an apparatus for forming a wall of a hollow structure;

[0062] Fig. n is a cross-sectional view of part of a wall formed by the apparatus of Fig. io;

[0063] Fig. 12 is a s cross-sectional side view of a part of another embodiment of a wall of a hollow structure, the wall comprising an inflatable bladder;

[0064] Fig. 13 is a side view of another embodiment of an apparatus for forming a wall of a hollow structure;

[0065] Fig. 14 is a cross-sectional view of part of a wall formed by the apparatus of Fig. 13;

[0066] Fig. 15 is a block diagram schematically illustrating an embodiment of a method of forming a wall of a hollow structure for use in a space environment;

[0067] Fig. 16 is a cross-sectional side view of an embodiment of a hollow structure for use in a space environment;

[0068] Fig. 17 is a perspective view of the hollow structure of Fig. 16;

[0069] Fig. 18 is a cross-sectional side view of another embodiment of a hollow structure for use in a space environment;

[0070] Fig. 19 is a cross-sectional side view of another embodiment of a hollow structure for use in a space environment;

[0071] Fig. 20 is a cross-sectional side view of another embodiment of a hollow structure for use in a space environment;

[0072] Fig. 21 is a cross-sectional side view of another embodiment of a hollow structure for use in a space environment; Fig. 22 is a cross-sectional side view of another embodiment of a hollow structure for use in a space environment;

[0073] Fig. 23 is a block diagram schematically illustrating steps an embodiment of a method of forming a hollow structure for use in a space environment; and,

[0074] Fig. 24 is a side view of an apparatus for forming a hollow space structure for use in a space environment. Detailed Description of the Invention

[0075] Referring now to Figs. 1 to 8, an embodiment of an apparatus 1 for forming a wall 100B of a hollow structure too for use in a space environment is shown. In the present example, the hollow structure too is a habitable structure too. However, in other embodiments, the hollow structure too may not be a habitable structure.

[0076] The apparatus i comprises a supply mechanism 2 configured to receive a supply 3 of sheet material 3A. In the present example, the supply 3 of sheet material 3A is a roll 3 of sheet material 3A.

[0077] The apparatus 1 further comprises a structure forming mechanism 4 that is configured to form the wall 100B of the habitable structure too. In use, sheet material 3A is fed from the supply mechanism 2 to the structure forming mechanism 4. That is, sheet material 3A is unravelled / unrolled from the roll 3 and is fed to the structure forming mechanism 4. The structure forming mechanism 4 guides the sheet material 3A into the shape of a hollow structure too. In the present embodiment, the wall 100B of the habitable structure too is tubular, comprising a central void 100A surrounded by a cylindrical tubular peripheral wall 100B.

[0078] The supply mechanism 2 comprises a holder 6 on which the roll 3 of sheet material 3A is received. In the present example, the holder 6 is a bobbin 6. In some embodiments, the holder 6 is configured to rotate as the sheet material 3A is fed from the roll 3 to the structure forming mechanism 4. In other embodiments, the holder 6 may remain stationary such that the roll 3 rotates relative to the holder 6.

[0079] The structure forming mechanism 4 comprises one or more guide members 5 configured to guide the sheet material 3A to advance about a conveyance axis (shown by chain-dashed line ‘X-X’ in Figs. 2 and 6) and in a first axial direction (shown by arrow ‘A’ in Figs. 2 and 6) along the conveyance axis X-X to form the wall 100B of the habitable structure too.

[0080] In the present embodiment, the one or more guide members 5 is configured to guide the sheet material 3A to advance about the conveyance axis X-X and in the first axial direction ‘A’ along the conveyance axis X-X such that the sheet material 3A follows a helical or substantially helical path. The or at least one of the guide members 5 may comprise a guide roller 5. However, it should be recognised that in other embodiments (not shown), the guide member(s) may take a different form. For example, one or more of the guide members 5 may comprise a moving belt for guiding the sheet material 3A. In another embodiment (not shown), one or more of the guide members 5 comprises a track for guiding the sheet material 3A. In one such embodiment (not shown), the structure forming mechanism 4 comprises a single guide member 5 in the form of a helical or corkscrew shaped track that is configured to guide the sheet material 3A along the track such that the sheet material 3A follows a helical path. In some embodiments, the or each guide member 5 may be stationary. In other embodiments, the or each guide member 5 may move to accommodate movement of the sheet material 3A, for example, comprising a roller or belt. In the present example, the structure forming mechanism 4 comprises a plurality of guide members 5. More specifically, the structure forming mechanism 4 comprises first, second, third and fourth guide members 5A, 5B, 5C, 5D which optionally are first, second, third and fourth rollers 5A, 5B, 5C, 5D. When the sheet material 3A is fed from the supply mechanism 2 to the structure forming mechanism 4, an end of the sheet material 3A first comes into contact with the first and second guide members 5A, 5B. The first and second guide members 5A, 5B are arranged as a pair of rollers 5A, 5B such that the sheet material 3A is urged between the rollers 5A, 5B as the sheet material 3A is fed from the supply mechanism 2 to the structure forming mechanism 4. The first and second rollers 5A, 5B are arranged such that as the sheet material 3A exits the rollers 5A, 5B it curves in a direction generally towards the third guide member 5C. For example, in the present example the first and second rollers 5A, 5B are angled such that the sheet material 3A curves in a direction generally towards the third guide member 5C. Alternatively, or additionally, the first and second rollers 5A, 5B may be respectively sized to induce curvature of the sheet material 3A as it exits the rollers 5A, 5B. For example, the diameter of the second roller 5B may be smaller than the diameter of the first roller 5A. The first and second rollers 5A, 5B may form an ‘English wheel’ configuration to cause the sheet material 3A to follow a curved path as it exits the rollers 5A, 5B. The third and fourth rollers 5C, 5D may optionally be omitted. The end of the sheet material 3A then comes into contact with the third guide member 5C as the sheet material 3A is advanced, causing the sheet material 3A to curve in a direction generally towards the fourth guide member 5D. The end of the sheet material 3A then comes into contact with the fourth guide member 5D, causing the sheet material 3A to curve in a direction generally towards the pair of first and second guide members 5A, 5B. The end of the sheet material 3A then comes again into contact with the first and second guide members 5A, 5B to again pass between the first and second guide members 5A, 5B, such that a loop of the sheet material 3A is formed.

[0081] In another embodiment (not shown), an initial loop of the sheet material 3A may be formed after loading of the sheet material 3A into the supply mechanism 2 and before the apparatus 1 is transported to the space environment. That is, the structure forming mechanism 4 may be pre-loaded with the sheet material 3A. For example, an initial loop of the sheet material 3A may be formed by manipulating the sheet material 3A by hand or using one or more robots such that the sheet material 3A abuts each of the first, second, third and fourth guide members 5A, 5B, 5C, 5D and a loop is formed. Optionally, the joining mechanism 10, described below, may be operated to retain the initial loop of the sheet material 3A in position or a fastener (for example, a clamp, staple or portion of adhesive) may be used to retain the initial loop in position. The apparatus 1 may then be transported to the space environment, and then the apparatus 1 operated such that sheet material 3A is fed from the supply 3 to the structure forming mechanism 4 to increase the axial length (shown by arrow ‘L’ in Figs. 2 and 7) of the hollow structure too and thus form the final wall 100B of the habitable structure too.

[0082] The guide members 5 are therefore configured to guide the sheet material 3A to advance about the conveyance axis X-X and in the first axial direction ‘A’ along the conveyance axis X-X to form the wall 100B of the habitable structure too.

[0083] Continued feeding of the sheet material 3A from the supply mechanism 2 to the structure forming mechanism 4 will cause further loops of the wall 100B of the habitable structure too to be continuously formed such that the axial length ‘L’ of the wall 100B of the habitable structure too is increased.

[0084] In the present example, the one or more guide members 5 are positioned about the conveyance axis X-X. In some embodiments, at least one guide member 5 is positioned generally on an opposite side of the conveyance axis X-X to another guide member 5. However, it should be recognised that different forms and arrangements of guide member 5 are possible that still would guide the sheet material 3A to advance about the conveyance axis X-X and in the first axial direction ‘A’ along the conveyance axis X-X to form the wall 100B of the structure too. For instance, in one embodiment the guide members 5 consist of a pair of guide rollers, wherein a guide roller nearer to the conveyance axis X-X is of smaller diameter than a second guide roller that is on the other side of the sheet material 3A and thus further away from the conveyance axis X-X (and the pair of guide rollers may form an ‘English wheel’ configuration).

[0085] The apparatus 1 comprises a drive 7 that, in use, is operable to urge the sheet material 3A to be fed from the supply mechanism 2 to the structure forming mechanism 4.

[0086] In the present example, the drive 7 comprises an actuator 8 and first and second drive members 9A, 9B.

[0087] The actuator 8 may be an electric motor 8. The actuator 8 may be coupled to one or both of the drive members 9A, 9 B via a gearbox (not shown).

[0088] The first and second drive members 9A, 9B may be first and second drive rollers 9A,9B. The actuator 8 is configured to drive one or both of the first and second drive members 9A, 9B. This causes sheet material 3A located between the first and second drive members 8 to be drawn from the roll 3 of sheet material 3A and conveyed towards the guide members 5. Thus, operation of the drive 7 causes the sheet material 3A to advance about the conveyance axis X-X and in an axial direction ‘A’ along the conveyance axis X-X to form the wall 100B of the habitable structure too.

[0089] In the present example, the actuator 8 is configured to drive the first drive roller 9A in a first rotational direction (in a clockwise direction from the perspective of Fig. 1) and to drive the second drive roller 9B in an opposite second rotational direction (in an anticlockwise direction from the perspective of Fig. 1). This causes the sheet material 3A located between the drive rollers 9 A, 9 B to be advanced towards the structure forming mechanism 4.

[0090] The drive 7 is therefore operable to vaiy the axial length ‘L’ of the wall 100B of the habitable structure too. That is, the more sheet material 3A that is fed from the supply mechanism 2 to the structure forming mechanism 4 due to operation of the drive 7, the greater the amount of sheet material 3A that is guided about the conveyance axis X-X and in the axial direction ‘A’ along the conveyance axis X-X to form the wall 100B and thus the greater the axal length ‘L’ of the wall 100B of the habitable structure too. The structure forming mechanism 4 comprises a joining mechanism 10 that is configured to join a first portion 11A of the sheet material 3A to a second portion 11B of the sheet material 3A such that the sheet material 3A is retained in the form of the wall 100B of the habitable structure too. That is, the joining mechanism 10 is configured to prevent the sheet material 3A of the wall 100B of the habitable structure too unwinding after the sheet material 3A has been formed into the shape of the wall 100B.

[0091] The first portion nA of the sheet material 3A is on an inner surface 15A of the sheet material 3A that is in proximity to a first longitudinal edge 3B of the sheet material 3A. The inner surface 15A of the sheet material 3A faces radially inwardly when the sheet material 3A is formed into the wall 100B of the habitable structure too. The inner surface 15A of the sheet material 3A may optionally form an interior surface of the wall 100B of the habitable structure too.

[0092] The second portion 11B of the sheet material 3A is on an outer surface 15B of the sheet material 3A that is in proximity to a second longitudinal edge 3C of the sheet material 3A that is opposite to the first longitudinal edge 3B. The outer surface 15B of the sheet material 3A faces radially outwardly when the sheet material 3A is formed into the wall 100B of the habitable structure too. The outer surface 15B of the sheet material 3A may optionally form an exterior surface of the wall 100B of the habitable structure too.

[0093] The joining mechanism 10 is arranged to join the first and second portions 11A, 11B together once that sheet material 3A has been arranged into a loop of sheet material 3A that subtends about the conveyance axis X-X. In the present example, the joining mechanism 10 is located in proximity to the first and second guide rollers 5A, 5B. For example, the joining mechanism 10 could be arranged at, before, or after the first and second guide rollers 5A, 5B relative to the direction of conveyance of the sheet material 3A. However, it should be recognised that in other embodiments the joining mechanism 10 could be positioned differently, for example, in proximity to the third or fourth rollers 5C, 5D and optionally may join the first and second portions nA, 11B together once several loops of the sheet material 3A of the wall 100B of the habitable structure too have been formed. When the sheet material 3A is arranged by the one or more guide members 5 to form the wall 100B of the habitable structure too, the first portion nA of the sheet material 3A overlaps the second portion 11B of the sheet material 3A to form an overlapping region (shown by arrow ‘J’ in Figs. 6 and 7). The joining mechanism 10 then joins the first portion nA to the second portion 11B in the overlapping region ‘J’ such that the sheet material 3A is retained in the form of the wall 100B of the habitable structure too. Optionally, the join of the overlapping region ‘J’ forms a seal between the first and second portions nA, 11B to prevent the ingress of air or moisture out of the wall 100B of the habitable structure too.

[0094] In one embodiment, the overlapping region ‘J’ is at least 5% of the width of the sheet material 3A measured in the first axial direction ‘A’ and, preferably, is at least 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45% or 50% of the width of the sheet material 3A.

[0095] In one embodiment, the overlapping region ‘J’ is at most 50% of the width of the sheet material 3A measured in the first axial direction ‘A’ and, optionally, is at most 40%, 30% or 25% or 20% of the width of the sheet material 3A. In some embodiments, the overlapping region ‘J’ is in the range of 5% to 50 % of the width of the sheet material 3A measured in the first axial direction ‘A’ and, preferably, is in the range of 10% to 50% of the width of the sheet material 3A.

[0096] It should be recognised that the above examples of the size of overlapping region ‘J’ are examples only and that other sizes of overlap are possible.

[0097] The joining mechanism 10 comprises a heater 12 configured to heat the sheet material 3A. The heater 12 may be configured to melt at least one of the first and second portions 11A, 11B of the sheet material 3A such that said portion nA, 11B subsequently cools and solidifies to join the first and second portions 11A, 11B of the sheet material 3A.

[0098] In the present example, the sheet material 3A comprises a thermoplastic that is melted by the heater 12 and subsequently cools and solidifies to join the first and second portions 11A, 11B of the sheet material 3A. The sheet material 3A may be a composite material. The sheet material 3A may comprise a reinforcement material and a matrix material. The reinforcement material may be, for example, pre-impregnated with the matrix material. The reinforcement material may be, for example, carbon fibre. The matrix material may be, for example, a thermoplastic or resin. The sheet material 3A may be a carbon-fibre reinforced polymer.

[0099] In the present example, the sheet material 3A is a carbon-fibre reinforced thermoplastic. In another example, the sheet material 3A may comprise a thermoplastic without carbon-fibre reinforcement.

[0100] In the present example, the sheet material 3A comprises one or more susceptor regions (depicted by the chain-dashed feature 13 in Fig. 5) that are configured to be inductively heated by the heater 12. The heater 12 is configured to generate an electromagnetic field to inductively heat the susceptor region 13. For example, the heater 12 may comprise one or more coils of wire (not shown) connected to a current source (not shown), which may be an AC source. The one or more coils may be connected to a DC source (e.g. a batteiy or solar panel) via an inverter that generates an AC signal.

[0101] The susceptor region(s) 13 may extend continuously or intermittently along the length of the sheet material 3A. In the present example, the susceptor region 13 is adjacent the first longitudinal edge 3B of the sheet material 3A. The susceptor region(s) 13 may be in the form of a mesh 13. The susceptor region(s) 13 may comprise, for example, a ferromagnetic material such as iron or steel. The susceptor region 13 may be embedded in the sheet material 3A or may be attached to a surface of the sheet material 3A by adhesive or during curing / cooling of the thermoplastic during manufacture of the sheet material 3A.

[0102] When the heater 12 is operated to inductively heat the susceptor region 13, the heat is transferred to the thermoplastic material of the sheet material 3A to melt the thermoplastic material in proximity to the susceptor region 13. The susceptor region 13 is located in proximity to the overlapping region ‘J’ of the first and second portions nA, 11B of the sheet material 3A. Therefore, the thermoplastic material is melted in the overlapping region ‘J’ and subsequently cools and solidifies such that a join is formed in the overlapping region ‘J’. That is, the thermoplastic material cools and solidifies once the sheet material 3A is formed into a loop, such that the sheet material 3A is retained as a loop. It should be recognised that the heater 12 may heat the sheet material 3A once it has been formed into a loop, or may heat the sheet material 3A prior to the sheet material 3A being formed into a loop.

[0103] In another example, the heater 12 is configured to inductively heat the carbon-fibre of the sheet material 3A. For instance, the heater 12 may be positioned in proximity to the overlapping region ‘J’ so that primarily the carbon-fibre of the sheet material 3A in the overlapping region ‘J’ is inductively heated. Therefore, the heater 12 also primarily heats the thermoplastic of the sheet material 3A in the overlapping region ‘J’ (and thus this subsequently cools to form a bond at the overlapping region ‘J’) and the remaining thermoplastic of the sheet material 3A is subjected to less or no heating. In the present example, the heater 12 heats the thermoplastic material inductively.

[0104] However, it should be recognised that in other embodiments (not shown), the heater may heat the thermoplastic material by other means, for example, conductively and / or radiatively. In one embodiment (not shown), the heater 12 comprises a conductive heat element (for example, a heated roller) that contacts the first portion nA of the sheet material 3A to heat the thermoplastic material. Alternatively, the heater 12 may contact the entire, or substantially the entire, inner surface 15A of the sheet material 3A but wherein thermoplastic material (or a suitable adhesive) is only applied over the first portion nA of the sheet material 3A. In some embodiments (not shown), the thermoplastic material (or suitable adhesive) is heated by a laser.

[0105] In other embodiments (not shown), the heater 12 may be configured to heat the outer surface 15B of the sheet material 3A and / or the thermoplastic / adhesive may be applied to the outer surface 15B. In some embodiments (not shown), the sheet material 3A comprises a thermoplastic strip / tape that is applied to the first portion 11A of the sheet material 3A.

[0106] In the above embodiments, the heater 12 is configured to heat a thermoplastic material of the sheet material 3A such that a portion of the thermoplastic material at the overlapping region ‘J’ is melted and subsequently cools to form a join. In other embodiments, the sheet material 3A may comprise a heat activated adhesive (which may optionally be a thermoplastic) that, for example, may be applied to the entire inner surface 15A of the sheet material 3A or only over the first portion 11A of the sheet material 15A. Thermoplastic may be omitted from the sheet material 3A. In some embodiments, the apparatus 1 is configured to press the first and second portions 11A, 11B of the sheet material 3A towards each other to facilitate the joining of the first and second portions nA, 11B.

[0107] The first and second guide rollers 5A, 5B are arranged to press the overlapping region ‘J’ of the first and second portions nA, 11B of the sheet material 3A towards each other as the sheet material 3A passes between the rollers 5A, 5B. This helps to hold the first and second portions 11A, 11B together as the thermoplastic material cools and solidifies and thus improves the bond therebetween. However, it should be recognised that the apparatus 1 may alternatively, or additionally, comprise another roller (not shown) to press the overlapping region ‘J’ of the first and second portions 11A, 11B of the sheet material 3A against the third or fourth guide roller 5C, 5D or against another component of the apparatus 1 in order to squeeze the first and second portions 11A, 11B towards each other. Additionally, or alternatively, the apparatus 1 may comprise for example, a belt, a reciprocating member (for example, that repeatedly stamps / presses the overlapping region ‘J’ to press the first and second portions 11A, 11B together) or a static component to press the first and second portions nA, 11B of the sheet material 3A towards each other.

[0108] It should be recognised that in other embodiments (not shown) the apparatus 1 is not configured to press the first and second portions nA, 11B of the sheet material 3A towards each other to facilitate the joining of the first and second portions nA, 11B. For instance, the second guide member 5B may be omitted in some embodiments. In some embodiments, the first and second portions 11A, 11B of the sheet material 3A are not pressed together after the first portion 11A is heated by the heater 12.

[0109] It should also be recognised that in some embodiments (not shown) the heater 12 does not melt the sheet material 3A to join the first and second portions 11A, 11B and instead the heat may, for example, cure an adhesive that is applied to the sheet material 3A. In yet another embodiment (not shown), the joining mechanism 10 does not comprise a heater 12. The first and second portions nA, 11B of the sheet material 3A may be joined together by, for example, an adhesive that is applied to the sheet material 3A in liquid form and dries / cures / cools to join the first and second portions 11A, 11B. The liquid adhesive may be applied by, for example, spraying, brushing, rolling or printing the adhesive onto the sheet material 3A. In the present example, the joining mechanism 10 is configured such that the overlapping region ‘J’ of the first and second portions 11A, 11B (which, in the present example, is joined by the solidified thermoplastic) subtends continuously about the conveyance axis X-X to form a hermetic seal. In the present example, the overlapping region ‘J’ that is joined by the solidified thermoplastic follows a substantially helical path about the conveyance axis X-X.

[0110] The apparatus 1 further comprises a cutting device 16 that is configured to separate the wall 100B of the habitable structure too from the supply 3 of sheet material 3A. In the present example, the cutting device 16 is configured to cut the sheet material 3A to separate the wall 100B of the habitable structure too. The cutting device 16 may comprise, for example, one or more cutting blades, saws, knives or laser cutting devices (not shown).

[0111] Once the wall 100B of the habitable structure too has been separated from the supply 3 of sheet material 3A, the wall 100B of the habitable structure too may be enclosed by first and second end walls to form an enclosed space, as described in more detail below. The enclosed space may form an environmental chamber that is hermetically sealed from the space environment and pressurised such that it is suitable for human habitation.

[0112] Advantageously, the supply 3 of sheet material 3A can be transported to the space environment and then the longer and larger-volume wall 100B of the habitable structure too can be formed from the supply 3, wherein the supply 3 occupies a smaller volume and is shorter and therefore is easier and less expensive to transport.

[0113] The diameter D of the wall 100B of the habitable structure too may be at least 2 metres and, preferably, at least 3, 4, 5, 10 15, 20, 25, 30, 40 or 50 metres.

[0114] The diameter D of the wall 100B of the habitable structure too refers to the external diameter D of the wall 100B of the habitable structure too. The axial length L of the wall 100B of the habitable structure too may be at least 2 metres and, preferably, maybe at least 3, 4, 5, 10, 15, 20, 25, 30, 35, 40 or 50 metres.

[0115] In some embodiments, the axial length L of the hollow structure too may be in the range of 3 to 50 metres.

[0116] It should be recognised that the above diameters D and axial lengths L of the wall 100B of the habitable structure too are examples only and other dimensions of the wall 100B of the habitable structure too are possible.

[0117] The apparatus 1 comprises a base 17. The components of the apparatus 1 such as the supply mechanism 2, structure forming mechanism 4, drive 7, joining mechanism 10 and cutting device 16 are mounted to the base 17. In some embodiments, the base 17 is mounted to a spacecraft (not shown in the embodiment of Figs. 1 to 8). The spacecraft may comprise the apparatus 1.

[0118] The structure forming mechanism 4 comprises first, second and third arms 18A, 18B, 18C that extend from the base 17. The first, second and third arms 18A, 18B, 18C may extend from the base 17 in different directions. The first, second and third arms 18A, 18B, 18C may extend in the same plane. The first, second, third and fourth guide members 5A, 5B, 5C, 5D are mounted to the base 17, and optionally via one or more of the arms 18A, 18B, 18C.

[0119] The apparatus 1 further comprises a fourth arm 18D that extends from the base 17 and to which the supply mechanism 2 is connected. In particular, the holder 6 is connected to the fourth arm 18D such that the roll 3 is suspended on the fourth arm 18D.

[0120] In the present embodiment, the or at least one of the guide members 5A, 5B, 5C, 5D is adjustable to adjust the size of the wall 100B of the habitable structure too that is produced by the structure forming mechanism 4. For example, the position of one or more of the guide members 5A, 5B, 5C, 5D relative to the base 17 may be adjustable to adjust the size of the hollow structure too.

[0121] Each of the first, second and third arms 18A, 18B, 18C comprises a respective track 19A, 19B, 19C. The apparatus 1 further comprises an adjustment system 20 that is configured to move the first guide member 5A along the track 19A of the first arm 18A and also in a direction perpendicular to the track 19A, to move the third guide member 5C along the track 19B of the second arm 18B and to move the fourth guide member 5D along the track 19C of the third arm 18C. In the present example, the adjustment system 20 comprises a first adjustment mechanism 20A that is configured to move the first guide member 5A along the track 19A of the first arm 18A and also in a direction perpendicular to the track 19A, a second adjustment mechanism 20B that is configured to move the third guide member 5C along the track 19B of the second arm 18B, and a third adjustment mechanism 20C that is configured to move the fourth guide member 5D along the track 19C of the third arm 18C.

[0122] In an alternative embodiment (not shown), the first and second guide members 5A, 5B do not change position relative to the first arm 18A, except that the first and second guide members 5A, 5B are each a roller 5A, 5B that rotates about a respective rotational axis. The track 19A of the first arm 18A facilitates pre-adjustment of the position of the first and second guide members 5A, 5B during assembly of the structure forming mechanism 4, and then the position of the first and second guide members 5A, 5B is fixed. For instance, the first and second guide member 5A, 5B may be bolted to the first arm 18A at one of various positions along the length of the first arm 18A. However, it should be recognised that in other embodiments (not shown), the track 19A of the first arm 18A may be omitted.

[0123] The first guide roller 5A may comprise a support element (not shown) that slidably engages the track 19A of the first arm 18A and a bearing (not shown) that rotatably couples the first guide roller 5A to the support element. The third guide roller 5C may comprise a support element (not shown) that slidably engages the track 19B of the second arm 18B and a bearing (not shown) that rotatably couples the third guide roller 5C to the support element. Similarly, the fourth guide roller 5D may comprise a support element (not shown) that slidably engages the track 19C of the third arm 18C and a bearing (not shown) that rotatably couples the fourth guide roller 5D to the support element. Each support element may be provided on a pair of rails (not shown) within the respective track 19B, 19C to permit sliding movement of the support element relative to the track 19B, 19C upon operation of the respective adjustment mechanism 20A, 20B. The first adjustment mechanism 20A is operable to move the first guide member 5A in a first adjustment direction relative to the first arm 18A (shown by arrow ‘Bl’ in Fig. 4, in which the tracks 19A-C are omitted for illustrative purposes) and in a second adjustment direction relative to the first arm 18A (shown by arrow ‘B2’ in Fig. 4) such that the position of the first guide member 5A along the track 19A can be adjusted. In addition, the first adjustment mechanism 20A is operable to move the first guide member 5A in a third adjustment direction relative to the first arm 18A (shown by arrow ‘B3’ in Fig. 4) and in a fourth adjustment direction relative to the first arm 18A (shown by arrow ‘B4’ in Fig. 4) such that the position of the first guide member 5A in a direction perpendicular to the track 19A can be adjusted. The third adjustment direction ‘B3’ is generally in a direction away from the wall 100B of the habitable structure too. The fourth adjustment direction ‘B4’ is opposite to the third linear direction ‘B3’. The first and second adjustment directions ‘Bl’ and ‘B2’ are generally along the first arm 18A and are perpendicular to the second and third adjustment directions ‘B3’ and ‘B4’. In the present example, the first to fourth adjustment directions ‘Bl’ to ‘B4’ are linear.

[0124] The first adjustment mechanism 20A comprises a rotary motor (not shown) and a linear gear mechanism (not shown), for example, a rack and pinion gear, lead screw or a cam and follower configured to translate rotational movement of the motor into linear movement of the first guide member 5A relative to the second guide member 5B. Additionally, or alternatively, the first adjustment mechanism 20A may comprise, for example, a linear motor or a pneumatic or hydraulic drive that is configured to move the first guide member 5A in the first to fourth adjustment directions ‘Bl’ to ‘B4’.

[0125] The second adjustment mechanism 20B is operable to move the third guide member 5C in a fifth adjustment direction relative to the second arm 18B (shown by arrow ‘B5’ in Figs. 3 and 4) and in a sixth adjustment direction relative to the second arm 18B (shown by arrow ‘B6’ in Figs. 3 and 4) such that the position of the third guide member 5C along the track 19B can be adjusted. The fifth adjustment direction ‘B5’ is generally in a direction away from the wall 100B of the habitable structure 100. The sixth adjustment direction ‘B6’ is opposite to the fifth linear direction ‘B5’. In the present example, the fifth and sixth adjustment directions ‘B5’ and ‘B6’ are linear. The second adjustment mechanism 20B comprises a rotary motor (not shown) and a linear gear mechanism (not shown), for example, a rack and pinion gear, lead screw or a cam and follower configured to translate rotational movement of the motor into linear movement of the third guide member 5C. Additionally, or alternatively, the second adjustment mechanism 20B may comprise, for example, a linear motor or a pneumatic or hydraulic drive that is configured to move the third guide member 5C in the fifth and sixth adjustment directions ‘B5’ and ‘B6’.

[0126] The third adjustment mechanism 20C is operable to move the fourth guide member 5D in a seventh adjustment direction relative to the third arm 18C (shown by arrow ‘B7’ in Figs. 3 and 4) and in an eighth adjustment direction relative to the third arm 18C (shown by arrow ‘B8’ in Figs. 3 and 4) such that the position of the fourth guide member 5D along the track 19C can be adjusted. The seventh adjustment direction ‘B7’ is generally in a direction away from the wall 100B of the habitable structure too. The eighth adjustment direction ‘B8’ is opposite to the seventh adjustment direction ‘B7’. In the present example, the seventh and eighth adjustment directions ‘B7’ and ‘B8’ are linear.

[0127] The third adjustment mechanism 20C comprises a rotary motor (not shown) and a linear gear mechanism (not shown), for example, a rack and pinion gear, lead screw or a cam and follower configured to translate rotational movement of the motor into linear movement of the fourth guide member 5D. Additionally, or alternatively, the third adjustment mechanism 20C may comprise, for example, a linear motor or a pneumatic or hydraulic drive that is configured to move the fourth guide member 5D in the seventh and eighth adjustment directions ‘B7’ and ‘B8’. The adjustment system 20 is configured to move the first, third and fourth guide members 5A, 5C, 5D relative to the respective first, second and third arms 18A, 18B, 18C to adjust the diameter of the wall 100B of the habitable structure too. That is, the first adjustment mechanism 20A moves the first guide member 5A relative to the second guide member 5B in the first and third adjustment directions ‘Bl’ and ‘B3’ to increase the diameter of the hollow structure too (whilst maintaining the same, or substantially the same, gap between the first and second guide members 5A, 5B) whilst the second adjustment mechanism 20B moves the third guide member 5C in the fifth adjustment direction ‘B5’ and the third adjustment mechanism 20C moves the fourth guide member 5D in the seventh adjustment direction ‘B7’ to increase the diameter of the wall 100B of the habitable structure too. This is because such movement changes the relative position of the first and second guide rollers 5A, 5B and also causes the third and fourth guide members 5C, 5D to be spaced further from the conveyance axis X-X such that the guide members 5A, 5B, 5C, 5D guide the sheet material 3A around the conveyance axis X-X with a greater radius to the conveyance axis X-X. This is shown in Fig. 3, wherein the wall 100B of the habitable structure too has a relatively large diameter (shown by arrow ‘D 1’) .

[0128] Similarly, the first adjustment mechanism 20A is operable to move the first guide member 5A relative to the second guide member 5B in the second and fourth adjustment directions ‘B2’ and ‘B4’ to decrease the diameter of the wall 100B of the habitable structure too (whilst maintaining the same, or substantially the same, gap between the first and second guide members 5A, 5B) whilst the second adjustment mechanism 20B is operable to move the third guide member 5C in the sixth adjustment direction ‘B6’ and the third adjustment mechanism 20C moves the fourth guide member 5D in the eighth adjustment direction ‘B8’ to decrease the diameter of the wall 100B of the habitable structure too. This is because such movement changes the relative position of the first and second guide rollers 5A, 5B and causes the third and fourth guide members 5C, 5D to be spaced closer to the conveyance axis X-X such that the guide members 5A, 5B, 5C, 5D guide the sheet material 3A around the conveyance axis X-X with a smaller radius to the conveyance axis X-X. This is shown in Fig. 4, wherein the wall 100B of the habitable structure too has a relatively small diameter

[0129] (shown by arrow ‘D2’).

[0130] The or at least one of the guide members 5A, 5B, 5C, 5D is therefore adjustable to adjust the radius that the sheet material 3A is advanced about the conveyance axis X-X to adjust the diameter D of the wall 100B of the habitable structure too.

[0131] In the present example, one or more of the guide members 5A, 5B, 5C, 5D are moveable relative to the respective arms 18A, 18B, 18C. However, other embodiments (not shown), the guide members 5A, 5B, 5C, 5D may be fixed relative to the arms 18A, 18B, 18C and instead the arms 18A, 18B, 18C are moved relative to the base 17 to move the guide member(s) 5A, 5B, 5C, 5D and thus adjust the diameter of the wall 100B of the habitable structure too. For example, one or more of the arms 18A, 18B, 18C may be moved linearly by an adjustment system (not shown). In another embodiment, one or more of the arms 18A. 18B, 18C may be pivoted relative to the base 17 to adjust the position of the respective guide member(s) 5A, 5B, 5C, 5D and thus adjust the diameter of the wall 100B of the habitable structure too. In the above embodiment, the adjustment system 20 comprises a first adjustment mechanism 20A configured to adjust the relative position of the first and second guide members 5A, 5B, a second adjustment mechanism 20B configured to adjust the position of the third guide member 5C and a third adjustment mechanism 20C configured to adjust the position of the fourth guide member 5D. However, in other embodiments (not shown), the adjustment system 20 may comprise two adjustment mechanisms or a single adjustment mechanism that is configured to move a plurality of the guide members 5A, 5B, 5C, 5D and, for example, may be configured to move the third and fourth guide members 5C, 5D. In a yet further embodiment (not shown), only the position of one of the guide members 5A, 5B, 5C, 5D is adjusted by the adjustment system 20 to vaiy the diameter of the wall 100B of the hollow structure too and the position of the other guide members 5A, 5B, 5C, 5D may remain constant. In the present embodiment, the wall 100B of the habitable structure too is in the form of a tube too. The tube too is generally cylindrical. The tube too has a constant diameter (shown by arrow ‘D’ in Fig. 7) along the axial length ‘L’ of the hollow structure too. The tube too comprises a void 100A in the centre of the tube too. The void 100A forms a chamber that is suitable for human habitation.

[0132] The sheet material 3A may extend continuously between opposing axial ends of the hollow structure too.

[0133] Although in the above described embodiment the wall 100B of the habitable structure too is of constant diameter ‘D’, in alternative embodiments (not shown) the diameter ‘D’ of the wall 100B of the habitable structure too may vary. For example, a first axial length section of the wall 100B of the habitable structure too may be a first diameter and then a second axial length section of the wall 100B may be a second diameter that is greater or less than the first diameter. To manufacture such a wall 100B, the sheet material 3A may be fed to the structure forming mechanism 4 to form the first axial length section of the wall 100B and then the adjustment system 20 is operated to move the first, third and fourth guide members 5A, 5C, 5D in the first, third, fifth and seventh adjustment directions ‘Bi’, ‘B3’, ‘B5’, ‘B7’ (to increase the diameter of the remainder of the wall 100B) or in the second, fourth, sixth and eighth adjustment directions ‘B2’, ‘B4’, ‘B6’, ‘B8’ (to decrease the diameter of the remainder of the wall 100B). In some embodiments, the diameter of the wall 100B of the habitable structure too is tapered between the first and second axial length sections of different diameter.

[0134] In the above described embodiment, the drive 7 is operable to rotate one or both of the first and second drive rollers 9A, 9B. In other embodiments (not shown), the drive 7 is operable to move one or more other components of the apparatus 1 in order to urge the sheet material 3A to be fed from the supply mechanism 2 to the structure forming mechanism 4. For example, the drive 7 may be operable to rotate at least one of the guide members 5 to urge the sheet material 3A to be fed from the supply mechanism 2 to the structure forming mechanism 4. The drive rollers 9A, 9B may therefore be omitted.

[0135] In yet further embodiments, the drive 7 is operable to rotate one or more components of the supply mechanism 2 to urge the sheet material 3A to be fed from the supply mechanism 2 to the structure forming mechanism 4. For example, the supply mechanism 2 may comprise a roll holder (for example, a bobbin 6) that receives the roll 3 of the sheet material 3A, and wherein the drive 7 is operable to rotate the roll holder 6 to urge the sheet material 3A to be fed from the supply mechanism 2 to the structure forming mechanism 4A.

[0136] In the above described embodiment, the supply 3 is a roll 3 of sheet material 3A. However, in other embodiments (not shown), the supply 3 is other than roll. For example, the supply 3 may comprise folded sheet material 3A or sheet material 3A that is loosely gathered.

[0137] In some embodiments, the actuator 8 of the drive 7, the joining mechanism 10, cutting device 16, first adjustment mechanism 20A, second adjustment mechanism 20B and third adjustment mechanism 20C are connected to a controller 21 (shown in Fig. 8). The controller 21 may be configured to control operation of the actuator 8 of the drive 7, joining mechanism 10, cutting device 16, first adjustment mechanism 20A, second adjustment mechanism 20B and third adjustment mechanism 20C.

[0138] Referring now to Fig. 9, another embodiment of an apparatus 101 for forming a wall 100B of a hollow structure too for use in a space environment is shown. The apparatus 101 is similar to the apparatus 1 of the embodiment of Figs. 1 to 8, with like features retaining the same reference numerals. In the present example, the hollow structure 100 is a habitable structure too. However, in other embodiments, the hollow structure too may not be a habitable structure.

[0139] A difference is that the apparatus 101 is configured such that the diameter ‘D’ of the wall 100B of the habitable structure too formed by the apparatus 101 is significantly larger than the diameter ‘D’ of the wall 100B of the habitable structure too formed by the apparatus i of the embodiment of Figs, i to 8, or the apparatus 101 itself is made smaller relative to the structure too. The apparatus tot comprises a structure forming mechanism 104 comprising a plurality of guide members 105A, 105B, 105C, 105D. The guide members 105A, 105B, 105C, 105D are configured to guide the sheet material 3A to advance about a conveyance axis (not shown in Fig. 9) and in an axial direction (not shown in Fig. 9) along the conveyance axis to form the wall 100B of the habitable structure too. In the present embodiment, the guide members 105A, 105B, 105C, 105D are configured to guide the sheet material 3A to advance about the conveyance axis and in a first axial direction along the conveyance axis such that the sheet material 3A follows a substantially helical path. In the present example, the structure forming mechanism 104 comprises first and second guide members 105A, 105B that comprise a pair of first and second guide rollers 105A, 105B. The structure forming mechanism 104 further comprises third and fourth guide members 105C, 105D that comprise a pair of third and fourth guide rollers 105C, 105D. However, as with the embodiment of Figs. 1 to 8, it should be recognised that the guide member 105A, 105B, 105C, 105D may take a different form and / or the structure forming mechanism 104 may comprise a different number of guide members.

[0140] In use of the apparatus 101, the drive 7 is operated to feed sheet material 3A from the supply mechanism 2 to the structure forming mechanism 104. The sheet material 3A travels between the pair of first and second guide rollers 105A, 105B. The first and second rollers 105A, 105B are arranged such that as the sheet material 3A exits the rollers 105A, 105B it curves in a direction generally towards the pair of third and fourth guide rollers 105C, 105D. In the present example, the first roller 105A has a larger diameter than the second roller 105B, which causes the sheet material 3A to follow a curved path (this may be referred to as an “English wheel” configuration). The sheet material 3A then travels between the pair of third and fourth guide rollers 105C, 105D and is then directed towards the first and second guide rollers 105C, 105D to form a loop of sheet material 3A of the hollow structure too. Continued operation of the drive 7 causes further sheet material 3A to be fed between the first and second guide rollers 105A, 105B and between the third and fourth guide rollers 105C, 105D such that the axial length of the hollow structure too is increased. In another embodiment, the third and fourth guide rollers 105C, 105D are omitted.

[0141] In another embodiment (not shown), an initial loop of the sheet material 3A may be formed after loading of the sheet material 3A into the supply mechanism 2 and before the apparatus 101 is transported to the space environment. That is, the structure forming mechanism 104 may be pre-loaded with the sheet material 3A. For example, an initial loop of the sheet material 3A may be formed by manipulating the sheet material 3A by hand or using one or more robots such that the sheet material 3A abuts each of the first, second, third and fourth guide members 105A, 105B, 105C, 105D and a loop is formed. Optionally, the joining mechanism 10, described below, may be operated to retain the initial loop of the sheet material 3A in position or a fastener (for example, a clamp, staple or portion of adhesive) may be used to retain the initial loop in position. The apparatus 101 may then be transported to the space environment, and then the apparatus 101 operated such that sheet material 3A is fed from the supply 3 to the structure forming mechanism 104 to increase the axial length of the wall 100B of the habitable structure too and thus form the final configuration of the wall 100B of the habitable structure too. The structure forming mechanism 104 comprises a joining mechanism 10 that is configured to join a first portion (not shown) of the sheet material 3A to a second portion (not shown) of the sheet material 3A such that the sheet material 3A is retained in the form of the wall 100B of the habitable structure too. That is, the joining mechanism 10 is configured to prevent the sheet material 3A of the wall 100B of the habitable structure too unwinding after the sheet material 3A has been formed into the shape of the wall 100B of the habitable structure too. The joining mechanism 10 may comprise, for example, a heater 12 that operates in a similar manner to the heater 12 of the embodiment of Figs. 1 to 8 and may heat / melt a thermoplastic / adhesive of the sheet material 3A, which may also have any of the features of the sheet material 3A of the embodiment of Figs. 1 to 8. The apparatus 101 further comprises a cutting device (not shown) that is configured to separate the wall 100B of the habitable structure too from the supply 3 of sheet material 3A. The cutting device may have any of the features of the cutting device 16 of the apparatus 1 of Figs. 1 to 8.

[0142] Once the wall 100B of the habitable structure too has been separated from the supply 3 of sheet material 3A, the wall 100B may be used in the construction of a habitable structure too, as described in more detail below. The diameter D of the wall 100B of the habitable structure too refers to the external diameter D of the wall 100B of the habitable structure too.

[0143] The diameter D of the wall 100B of the habitable structure too may be at least 2 metres and, preferably, at least 3, 4, 5, 10 15, 20, 25, 30, 40 or 50 metres.

[0144] The axial length L of the wall 100B of the habitable structure too may be at least 2 metres and, preferably, maybe at least 3, 4, 5, 10, 15, 20, 25, 30, 35, 40 or 50 metres.

[0145] In some embodiments, the axial length L of the hollow structure too may be in the range of 3 to 50 metres.

[0146] It should be recognised that the above diameters D and axial lengths L of the wall 100B of the habitable structure too are examples only and other dimensions of the wall 100B of the habitable structure too are possible.

[0147] In the embodiment shown in Fig. 9, the guide members 105A, 105B, 105C, 105D are each rotatably mounted to a fixed location on the guide arms 18A, 18C and the diameter D of the wall 100B of the habitable structure too is not adjustable. However, in other embodiments (not shown) the apparatus 101 may comprise an adjustment system (not shown) that is configured to adjust the position of one or more of the guide members 105A, 105B, 105C, 105D to adjust the diameter D of the wall 100B of the habitable structure too that is produced by the structure forming mechanism 104. For example, the adjustment system may have any of the features of the adjustment system 20 of the apparatus 1 of Figs. 1 to 8. In one embodiment (not shown), the diameter D of the wall 100B of the habitable structure too may be gradually decreased as wall 100B is formed such that the wall 100B of the habitable structure too has a cone or dome shape or a truncated cone or dome shape. Optionally, the cone or dome may be closed at one end. In one embodiment, one (or both) of the first and second rollers 105A, 105B may be swapped with alternative rollers of a different diameter to vary the diameter of the wall 100B of the habitable structure too. For instance, the second roller 105B may be swapped with a different roller that has a smaller diameter to decrease the diameter of the wall 100B of the habitable structure too that is to be formed. The roller may be swapped, for example, be a robotic arm (not shown) of the apparatus 101.

[0148] Referring now to Fig. 10, another embodiment of an apparatus 201 for forming a wall 100B of a hollow structure too for use in a space environment is shown. An example of a portion of the wall 100B produced by the apparatus 201 is shown in Fig. 11. In the present example, the hollow structure too is a habitable structure too. However, in other embodiments, the hollow structure too may not be a habitable structure. The apparatus 201 is similar to the apparatus of the embodiment of Figs. 1 to 8, with like features retaining the same reference numerals.

[0149] A difference is that the apparatus 201 further comprises a layer provision mechanism 202 configured to provide a layer of material no that is arranged on the inside of the sheet material 3A of the wall 100B of the habitable structure too, although in an alternative embodiment the layer provision mechanism 202 is configured to provide a layer of material no that is arranged on the exterior of the sheet material 3A of the wall 100B of the habitable structure too. The layer of material no may be a sealing layer no configured to hermetically seal the interior of the habitable structure too or at least a portion of the interior of the habitable structure too. However, in other embodiments (not shown) the layer of material no may alternatively, or additionally, be configured to thermally insulate the wall 100B of the hollow structure too and / or to shield the interior of the wall 100B of the habitable structure too from radiation.

[0150] The layer provision mechanism 202 is configured to receive a supply 210 of a second sheet material no, which in the present embodiment is a roll 210 of the second sheet material no. The second sheet material no is fed from the supply 210 and provided to the interior or exterior of the wall 100B of the habitable structure too. The second sheet material no may be conveyed about the interior or exterior of the sheet material 3A of the wall 100B of the habitable structure too after the wall 100B of the habitable structure too has been formed. In another embodiment, the second sheet material no may be supplied as the wall 100B of the habitable structure too is formed from the sheet material 3A such that the second sheet material no moves in the first axial direction A as the sheet material 3A is advanced. For instance, an end of the second sheet material no may be attached to the sheet material 3A once a loop of the sheet material 3A has been formed, such that further movement of the sheet material 3A in the first axial direction A about the conveyance axis X-X also draws the sheet material no in the first axial direction A. The sheet material no may be attached to the sheet material 3A by being fed by the drive 7 to an adhesive region on the sheet material 3A or may be, for example, welded to the sheet material 3A or otherwise adhered thereto. As another example, the sheet material no may be positioned on the sheet material 3A (before or after the wall 100B of the habitable structure too has been formed) using a robotic arm, one or more rollers, or one or more conveyance belts.

[0151] In embodiments wherein the overlapping region ‘J’ of the wall 100B of the habitable structure too forms a hermetic seal, the layer of material no provides an additional sealing protection between the inside of the habitable structure too and the space environment. Alternatively, the overlapping region ‘J’ may not completely seal the inside of the hollow structure too, in which case the layer of material no optionally provides the hermetic seal between the space environment and the inside of the habitable structure too. However, it should be recognised that in other embodiments the interior of the wall 100B of the hollow structure too is not hermetically sealed. In some embodiments, the hollow structure too is not habitable. For example, the hollow structure too may be a fuel tank that is configured to store a propellant / other fuel. In some embodiments, the interior of the hollow structure too is not sealed from the space environment.

[0152] In some embodiments, the layer of material no is a sheet of material that circumscribes the conveyance axis to completely surround the conveyance axis. The ends of the sheet material no may overlap to form a seal such that the layer of material no is generally cylindrical. In some embodiments, one or both ends of the layer of material no may be sealed. For example, one end of the layer of material no may be sealed to form a cup-shape. In another example, both ends of the layer of material no may be sealed such that the layer of material no completely encloses a space within the layer of material no. The layer of material no may be provided with an access, for example, an airlock, to permit a person to enter and exit the interior of the layer of material no.

[0153] In another embodiment (not shown), the layer of material no may be sprayed on to the interior or exterior of the sheet material 3A of the wall 100B of the habitable structure too. The layer provision mechanism 202 may comprise a spray device (not shown) that is configured to spray the layer of material no (for example, in liquid or powder form) onto the sheet material 3A to form the layer of material no. In another embodiment, a layer of material may be integral with the sheet material 3A. The roll 3 of sheet material 3A may already comprise the layer of material.

[0154] Another example of a hollow structure too is shown in Fig. 12. In this example, the layer of material no is a bladder no. The bladder no may be formed from a flexible material, for example, a flexible polymer such as rubber. The bladder no may be inflatable. In some embodiments, the bladder no may comprise an enclosed space. One or both ends of the bladder no may be sealed.

[0155] The layer provision mechanism 202 may be configured to position the bladder no within the wall 100B of the habitable structure too after the wall 100B has been formed from the sheet material 3A. Alternatively, the layer provision mechanism 202 may be configured to provide the bladder no as the wall 100B of the habitable structure too is formed from the sheet material 3A such that the bladder no moves in the first axial direction A as the sheet material 3A is advanced. The layer provision system mechanism 202 may comprise, for example, a robotic arm, one or more rollers, or one or more conveyance belts.

[0156] In some embodiments, the bladder no may have one or more sealable or resealable openings (not shown) to allow objects and / or people to enter or exit the bladder no. The opening may comprise an airlock. The airlock may be pre-manufactured and attached to the bladder no. The airlock may be part of a panel that is attached to the bladder no to provide a means of entering / exiting the bladder no.

[0157] The layer of material no may be flexible. In some embodiments, the layer of material no comprises a multi-layer insulation. The insulation may take any suitable form and may comprise, for example, composite foams or dual density foam layers. The layer of material no may be attached to the sheet material 3A of the wall 100B of the habitable structure too, for example, using an adhesive. In other embodiments, the layer of material no is not attached to the sheet material 3A. In one such embodiment, the layer of material no is an inflatable bladder no, wherein inflation of the bladder no causes the bladder no to be pressed against the inside of the sheet material 3A of the wall 100B of the habitable structure too such that the bladder no is retained in position relative to the sheet material 3A. Referring now to Fig. 13, another embodiment of an apparatus 301 for forming a wall 100B of a hollow structure too for use in a space environment is shown. The apparatus 301 is similar to the apparatus 1 of the embodiment of Figs. 1 to 8, with like features retaining the same reference numerals. The apparatus 301 is configured to produce the wall 100B shown in Fig. 14. In the present example, the hollow structure too is a habitable structure too.

[0158] A difference is that the apparatus 301 is configured such that the apparatus 301 further comprises a second sheet supply mechanism 302 configured to receive a supply 303 of second sheet material 303A. In the present example, the supply 303 of second sheet material 303A is a roll 303A. The second sheet material 303A may have any of the features of the sheet material 3A discussed above and, in the present example, is a carbon fibre reinforced thermoplastic. The sheet materials 3A, 303A may be the same or different. In the present example, the second sheet material 303A is an inner sheet material 303A that is provided radially inwardly of the sheet material 3A of the wall 100B. However, in another embodiment (not shown), the second sheet material 303A is instead provided externally of the sheet material 3A. The second sheet material supply mechanism 302 may operate in a similar manner to, and may have any of the features of, the supply mechanism 2 described above in relation to the apparatus 1 of Figs. 1 to 8.

[0159] The apparatus 301 is configured such that, in use, the second sheet material 303A is fed from the second sheet supply mechanism 302 to the structure forming mechanism 4. The one or more guide members 5A, 5B, 5C, 5D are configured to guide the second sheet material 303A to advance about the conveyance axis X-X and in the first axial direction A to be on the inside of the sheet material 3A of the wall 100B of the habitable structure too. That is, the second sheet material 303A is located radially inwardly towards the conveyance axis X-X relative to the sheet material 3A.

[0160] The apparatus 301 optionally further comprises a layer provision mechanism 202 configured to provide a layer of material no that is arranged on the inside of the sheet material 3A of the wall 100B of the habitable structure too. The layer provision mechanism 202 operates in a similar manner to that of the apparatus 201 of Fig. 10. In another embodiment (not shown), the sheet materials 3A, 303A may abut each other and the layer of material no may be provided on the interior of the second sheet material 303A and, optionally, may comprise an inflatable bladder no and / or a thermal insulation and / or radiation shielding. In another embodiment, the layer provision mechanism 202 is omitted. In some embodiments, the sheet material 3A and second sheet material 303A abut each other and the layer of material no is omitted.

[0161] The apparatus 301 is configured such that the wall 100B of the habitable structure too comprises a circumferential wall 100B with the sheet material 3A forming an exterior of the wall 100B, the second sheet material 303A forming an interior of the wall 100B, and the layer of material no being located between the sheet material 3A and second sheet material 303A.

[0162] The second sheet material 303A therefore improves the strength of the wall 100B of the habitable structure too and / or provides an additional hermetic seal and / or thermal insulation and / or radiation shielding between the interior of the habitable structure too and the space environment. In embodiments wherein the layer of material no is provided between the sheet materials 3A, 303A, the layer of material no is configured to provide a seal and / or thermal insulation and / or radiation shielding and / or to reinforce the wall 100B of the habitable structure too. In one such embodiment, the layer of material no itself comprises multi-layer insulation. In some embodiments, the layer of material no separates at least a portion of the sheet material 3A from at least a portion of the second sheet material 303A. In the present example, the structure forming mechanism 4 comprises first and second guide members 5A, 5B that comprise a pair of first and second guide rollers 5A, 5B. The structure forming mechanism 4 further comprises third and fourth guide members 5C, 5D that comprise third and fourth guide rollers 5C, 5D. The guide rollers 5A, 5B, 5C, 5D operate in a similar manner to those of the embodiment of Figs. 1 to 8, but instead guide all of the sheet material 3A, layer of material no and second sheet material 303A about the conveyance axis X-X and in the axial direction A. In the present example, the sheet material 3A, layer of material no and second sheet material 303A all follow a helical path. However, as with the embodiments of Figs. 1 to 12, it should be recognised that the guide members 5A, 5B, 5C, 5D may take a different form and / or the structure forming mechanism 4 may comprise a different number of guide members.

[0163] In the present example, the apparatus 303 is configured such that the sheet material 3A, layer of material no and second sheet material 303A are collected together to form a collation 310 of layers that are guided together about the conveyance axis X-X and in the first axial direction A.

[0164] In use of the apparatus 301, the drive 7 is operated to feed sheet material 3A from the supply mechanism 2 to the structure forming mechanism 4, to feed the layer of material no from the supply 210 to the structure forming mechanism 4 and to feed the second sheet material 303A from the supply 303 to the structure forming mechanism 4. In the present example, the sheet material 3A, layer of material no and second sheet material 303A are all fed between the same pair of drive rollers 9A, 9B that are rotated by the actuator (not shown) to advance the sheet material 3A, layer of material no and second sheet material 303A together as a collation 310 of layers. However, in other embodiments (not shown) different drives may be provided to advance each of the sheet material 3A, layer of material no and second sheet material 303A.

[0165] The sheet material 3A, layer of material no and second sheet material 303A travels between the pair of first and second guide rollers 5A, 5B. The first and second rollers 5A, 5B are arranged such that as the sheet material 3A, layer of material no and second sheet material 303A exits the rollers 5A, 5B it curves in a direction generally towards the third guide roller 5C. The sheet material 3A, layer of material no and second sheet material 303A is then guided by the third guide roller 5C towards the fourth guide roller 5D, and is then guided by the fourth guide roller 5D back to the first and second guide rollers 5A, 5B to form a loop of the sheet material 3A, layer of material no and second sheet material 303A that forms part of the wall 100B of the habitable structure too. Continued operation of the drive 7 causes further sheet material 3A, layer of material no and second sheet material 303A to be fed between the first and second guide rollers 5A, 5B, to the third guide roller 5C, fourth guide roller 5D and then back to the pair of first and second guide rollers 5A, 5B such that the axial length of the wall 100B of the habitable structure too is increased. In another embodiment (not shown), an initial loop of at least one of, or all of, the sheet material 3A, layer no and / or second sheet material 303A may be manually formed after loading of the sheet material 3A into the supply mechanism 2.

[0166] The structure forming mechanism 4 comprises a joining mechanism 10 that is configured to join a first portion (not shown) of the collation 310 of layers to a second portion (not shown) of the collation 310 of layers such that the sheet material 3A, layer of material no and second sheet material 303A is retained in the form of the wall 100B of the habitable structure too. That is, the joining mechanism 10 is configured to prevent the sheet material 3A, layer of material no and second sheet material 303A of the wall 100B of the habitable structure too from unwinding and / or separating after being formed into the shape of the wall 100B of the habitable structure too. The joining mechanism 10 may comprise, for example, a heater 12 that operates in a similar manner to the heater 12 of the embodiment of Figs. 1 to 8 and may heat / melt a thermoplastic / adhesive of the sheet material 3A or second sheet material 303A, either or both of which may also have any of the features of the sheet material 3A of the embodiment of Figs. 1 to 8. In some embodiments (not shown), the joining mechanism 10 comprises a first heater 12 that heats the sheet material 3A and a second heater (not shown) that heats the second sheet material 303A. In other embodiments, a single heater heats both of the sheet materials 3A, 303A, or instead only one of (or neither of) the sheet materials 3A, 303A is heated.

[0167] In the present example, a portion of an inner surface of the inner sheet material 303A overlaps a portion of an outer surface of the sheet material 3A and is attached thereto by the joining mechanism 10.

[0168] The apparatus 301 further comprises a cutting device (not shown) that is configured to separate the wall 100B of the habitable structure too from the supply 3 of sheet material 3A, the supply 210 of layer of material no and the supply 303 of second sheet material 303A. The cutting device may have any of the features of the cutting device 16 of the apparatus 1 of Figs. 1 to 8. Once the wall 100B of the habitable structure too has been separated from the supplies 3, 210, 303, the wall 100B of the habitable structure too may be used in the construction of a habitable structure too, as described in more detail below.

[0169] The additional layers of material no and second sheet material 303A may reinforce the wall 100B and / or help to provide additional sealing and / or thermal insulation and / or radiation shielding from the space environment. Referring now to Fig. 15, a block diagram illustrating a method 400 of forming a wall of a hollow structure for use in a space environment is shown. The method 400 comprises a first step (Si) of feeding sheet material from a supply of sheet material to one or more guide members. The method 400 further comprises a second step (S2) of using the one or more guide members to guide the sheet material to advance about a conveyance axis and in an axial direction along the conveyance axis to form the wall of the hollow structure. The hollow structure may be a habitable structure.

[0170] In each of the above described embodiments of apparatus 1, 101, 201, 301, the sheet material 3A, 303A is advanced in a first axial direction A to form the wall 100B of the hollow structure 100. Optionally, in some embodiments this process may be reversed.

[0171] That is, the direction of the drive may be reversed such that the sheet material 3A, 303A is drawn from the structure forming mechanism 4 to the supply mechanism 2 and collected on the supply 3, 303. The sheet material 3A, 303A can thus be advanced in a second axial direction that is opposite to the first axial direction A. This decreases the axial length ‘L’ of the wall 100B of the hollow structure too. This process may be performed after the wall 100B has been separated from other components of the hollow structure too during disassembly thereof. In some embodiments, the heater 12 of the joining mechanism 10 is operated to heat the thermoplastic / adhesive such that the thermoplastic / adhesive melts and thus the sheet material 3A, 303A can be drawn from the wall 100B and back to the supply 3, 303. Optionally, the supply 3, 303 may then be reused to construct one or more further wall(s) of a hollow structure too.

[0172] Referring now to Figs. 16 and 17, an embodiment of a hollow structure 1000 is shown.

[0173] The hollow structure 1000 comprises a peripheral wall 100B that is manufactured by any of the apparatus 1, 101, 201, 301 described herein. In the present example, the hollow structure 1000 is a habitable structure 1000. The habitable structure 1000 further comprises a first end wall toot and a second end wall 1002. The first and second end walls 1001, 1002 are provided at opposite first and second ends of the peripheral wall 100B to form a chamber 1000A inside the habitable structure 1000. The first and second end walls 1001, 1002 may, for example, be adhered or welded to the wall 100B or attached thereto using one or more fasteners.

[0174] In some embodiments, the first and / or second ends of the peripheral wall 100B are cut to shape to fit against the respective end walls 1001, 1002.

[0175] The end walls 1001, 1002 may be end panels. The end walls 1001, 1002 may be formed from the same sheet material as the sheet material 3A, 303A of the peripheral wall 100B described herein. The habitable structure 1000 comprises an access 1003, for example, an airlock 1003, to permit one or more persons to enter and exit the chamber 1000A. For example, the first and / or second end wall 1001, 1002 may comprise an airlock 1003 or other such access. In the present embodiment, the first end panel 1001 comprises the airlock 1003. The chamber 1000A is pressurised to form an environmental chamber that is suitable for human habitation. The chamber 1000A maybe an oxygen environment capable of sustaining life. The habitable structure 1000 may comprise an oxygen source (not shown), for example, an oxygen tank and / or oxygen recoveiy system. The chamber 1000A is hermetically sealed from the space environment. That is, the circumferential wall 100B and end walls 1001, 1002 together form a boundary of the chamber 1000A that hermetically seals the chamber 1000A from the space environment. The habitable structure 1000 is of a size suitable for human habitation. The habitable structure 1000 may be used, for example, for in-space or planetary applications such as the Earth’s Moon. The habitable structure 1000 may form, or form part of, an in-orbit fuel depot and refuelling station. The habitable structure 1000 may form, or form part of, a satellite. The habitable structure 1000 may form, or form part of, a building for use in a space environment. In other embodiments, the hollow structure 1000 is not a habitable structure. The hollow structure 1000 may not be sealed from the space environment. In one embodiment, the hollow structure 1000 is a fuel tank.

[0176] In the present example, the wall 100B is formed by the apparatus i of Figs, i to 8 or the apparatus tot of Fig. 9. However, the wall 100B could alternatively be formed by the apparatus 201 of Fig. 10 or the apparatus 301 of Fig. 13 (or another configuration of apparatus) and optionally may have an additional layer of material. Alternatively, the habitable structure 1000 may be formed by a different configuration of apparatus. Referring now to Fig. 18, another embodiment of a hollow structure 2000 is shown. In the present example, the hollow structure 2000 is a habitable structure 2000. The habitable structure 2000 is similar to the habitable structure 1000 of the embodiment of Figs. 16 and 17, with like features retaining the same reference numerals. The habitable structure 2000 comprises a peripheral wall 100B that is manufactured by the apparatus 201 of Fig. 10 and thus comprises a layer of material no. The layer of material no may be at least one of: a sealing layer, a thermally insulating layer, and / or a shielding layer.

[0177] In some embodiments, the sealing layer no is configured to hermetically seal the wall 100B or to provide an additional seal. In some embodiments, the layer of material no is a shielding layer configured to shield the interior 1000A of the habitable structure 2000 from radiation, for example, ionising radiation.

[0178] The first and second end walls 1001, 1002 also comprise respective layers of material 1004, 1005 that may also be, for example, at least one of: a sealing layer, a thermally insulating layer, and / or a shielding layer. The sealing layers 1004, 1005 may be attached to the respective end walls 1001, 1002 before or after assembly of the walls 100B, 1001, 1002 of the habitable structure 2000. The layer of material no may be flexible. In some embodiments, the layer of material no comprises a multi-layer insulation. The insulation may take any suitable form and may comprise, for example, composite foams or dual density foam layers.

[0179] In one embodiment, the layer of material no is sprayed on to the interior of the wall 100B, and optionally the interior of the end walls 1001, 1002, and may form one continuous layer. Referring now to Fig. 19, another embodiment of a hollow structure 3000 is shown. In the present example, the hollow structure 3000 is a habitable structure 3000. The habitable structure 3000 is similar to the habitable structure 1000 of the embodiment of Figs. 16 and 17, with like features retaining the same reference numerals. The habitable structure 3000 comprises a layer of material no comprising a bladder no.

[0180] The bladder no may be formed from a flexible material, for example, a flexible polymer such as rubber. The bladder no maybe inflatable. The bladder no has an open end 110A that is sealed about the airlock 1003 to allow one or more person(s) to enter and exit an interior chamber 1000A within the bladder no.

[0181] The layer of material no may be attached to the sheet material 3A of the wall 100B of the habitable structure 3000, for example, using an adhesive. In other embodiments, the layer of material no is not attached to the sheet material 3A. In one such embodiment, the layer of material no is an inflatable bladder no, wherein inflation of the bladder no due to pressurisation of the chamber 1000A causes the bladder no to be pressed against the inside of the sheet material 3A of the wall 100B of the habitable structure 3000 such that the bladder no is retained in position relative to the sheet material 3A.

[0182] In some embodiments, the bladder no is configured to hermetically seal the wall 100B or to provide an additional seal as a safety feature. In some embodiments, the bladder no is a shielding layer configured to shield the interior 1000A of the habitable structure 3000 from radiation, for example, ionising radiation, and / or provides thermal insulation of the interior 1000A.

[0183] Referring now to Fig. 20, another embodiment of a hollow structure 4000 is shown. In the present example, the hollow structure 4000 is a habitable structure 4000. The habitable structure 4000 is similar to the habitable structure 1000 of the embodiment of Figs. 16 and 17, with like features retaining the same reference numerals. The habitable structure 4000 comprises a peripheral wall 100B that is manufactured by the apparatus 301 of Fig. 13 and thus comprises a layer of material no and a second sheet material 303A. The layer of material no may be at least one of: a sealing layer, a thermally insulating layer, and / or a shielding layer. In some embodiments, the sealing layer no is configured to hermetically seal the wall 100B or to provide an additional seal. In some embodiments, the layer of material no is a shielding layer configured to shield the interior 1000A of the habitable structure 4000 from radiation, for example, ionising radiation, and / or provides thermal insulation of the interior 1000A. Optionally, the first and second end walls 1001, 1002 also comprise an additional layer of material.

[0184] The second sheet material 303A is provided on the interior of the wall 100B and the sheet material 3A is provided on the exterior of the wall 100B. The layer of material no is located between the sheet material 3A and the second sheet material 303A. In the present example, the layer of material no comprises thermal insulation and, preferably, comprises multi-layer thermal insulation. The first and / or second end walls 1001, 1002 may optionally also comprise respective layers of material 1004, 1005 that may be, for example, at least one of: a sealing layer, a thermally insulating layer, and / or a shielding layer. The sealing layers 1004, 1005 may be attached to the respective end walls 1001, 1002 before or after assembly of the walls 100B, 1001, 1002 of the habitable structure 4000.

[0185] In some embodiments, the first and second walls 1001, 1002 may comprise respective sheets of material 1001, 1002. The first and / or second end walls 1001, 1002 may optionally further comprise respective second sheets of material 1006, 1007 that are provided on the interior of the respective layers 1004, 1005. The layers of material 1004, 1005 may be multi-layer thermal insulation. The layer of material 1004 may be located between the sheet 1001 and second sheet 1006 of the first end wall 1001 and the layer of material 1005 may be located between the sheet 1002 and second sheet 1007 of the second end wall 1002. Referring now to Fig. 21, another embodiment of a hollow structure 5000 is shown. In the present example, the hollow structure 5000 is a habitable structure 5000. The habitable structure 5000 is similar to the habitable structure 1000 of the embodiment of Figs. 16 and 17, with like features retaining the same reference numerals. A difference is that the second end wall 1002 is omitted and instead an end of the peripheral wall 100B of the habitable structure 5000 is sealed against a surface S. The surface S may be a surface of a component of a spacecraft or other space structure. Alternatively, the surface S may be a lunar or planetary surface (i.e. other than Earth), or a building formation / pad formed in or on said lunar or planetary surface.

[0186] Referring now to Fig. 22, another embodiment of a hollow structure 6000 is shown. In the present example, the hollow structure 6000 is a habitable structure 6000. The habitable structure 6000 is similar to the habitable structure 1000 of the embodiment of Figs. 16 and 17, with like features retaining the same reference numerals. A difference is that the diameter of the circumferential wall 100B is tapered. Therefore, the first end wall 1001 is smaller than the second end wall 1002. It should be appreciated that any of the habitable structures 1000, 2000, 3000, 4000, 5000 may comprise a wall 100B with a tapered diameter or a constant diameter.

[0187] Referring now to Fig. 23, a block diagram illustrating a method 500 of forming a hollow structure for use in a space environment is shown. The method 500 comprises a first step (Si) of feeding sheet material from a supply of sheet material to one or more guide members. The method 500 further comprises a second step (S2) of using the one or more guide members to guide the sheet material to advance about a conveyance axis and in an axial direction along the conveyance axis to form the wall of the hollow structure. The wall may be a peripheral wall of the hollow structure. The method 500 further comprises a third step (S3) of enclosing at least one end of the wall. The third step (S3) may comprise enclosing at least one end of the wall to form a hermetically sealed chamber within the hollow structure. The method may be performed in the space environment. The hollow structure may be a habitable structure. In the present example, the method 500 comprises enclosing first and second ends of the wall. The method 500 comprises providing a first end wall at a first end of the wall and providing a second end wall at a second end of the wall.

[0188] The peripheral wall may be manufactured in the space environment. The first and / or second end walls may be transported to the space environment and attached to the peripheral wall to enclose a space within the habitable structure. Alternatively, one or both of the end walls may be manufactured in the space environment, for example, by 3D printing of the first and / or second end walls. The first and / or second end walls may be manually attached to the respective ends of the peripheral wall. That is, a person may manually manoeuvre the first and / or second end walls into position and attach the end walls to the peripheral wall, for example, by adhering, welding and / or using fasteners. Alternatively, an apparatus may be configured to move the first and / or second end walls into position and attach the end walls to the peripheral wall, for example, by adhering, welding and / or using fasteners. The apparatus may comprise, for example, a robotic arm.

[0189] Referring now to Fig. 24, an embodiment of an apparatus 600 for forming a hollow structure for use in a space environment is shown. The apparatus 600 comprises an apparatus (not shown) for forming a wall 100B of a hollow structure 1000 for use in a space environment, which may have any of the features of any of the embodiments of apparatus 1, 101, 201, 301 described herein. The hollow structure may be a habitable structure.

[0190] The apparatus 600 further comprises a device 601 for enclosing an end of the wall 100B. In the present example, the device 601 comprises a robotic arm 602.

[0191] The robotic arm 602 has a gripping device 603 configured to releasably grip the end wall 1001. The gripping device 603 may comprise, for example, robotic jaws 603. The robotic arm 602 may grip the end wall 1001, move the end wall 1001 into a fixing position relative to the peripheral wall 100B and then release the end wall 1001 once it has been attached to the peripheral wall 100B to enclose the end of the peripheral wall 100B. The end wall 1001 may be provided over, or within, the end of the peripheral wall 100B. In other embodiments (not shown), the device 601 alternatively, or additionally, comprises one or more belts, pulleys, or other actuators that are configured to position the end wall 1001 and attach the end wall 1001 to the peripheral wall 100B.

[0192] In some embodiments, the device 601 further comprises an attachment mechanism 604 that is configured to attach the end wall 1001 to the peripheral wall 100B. In the present example, the attachment mechanism 604 comprises an adhesive applicator 604 that is configured to apply adhesive to the end wall 1001 and / or peripheral wall 100B to attach these components of the habitable structure 1000 together. The adhesive applicator 604 comprises an adhesive supply 605 and a nozzle 606 that is configured to expel adhesive stored in the adhesive supply 605. In the present example, the nozzle 606 is mounted to the robotic arm 602. In another embodiment (not shown), the attachment mechanism 604 is configured to fuse / weld the end wall 1001 and peripheral wall 100B together. For example, the end wall 1001 and / or peripheral wall 100B may comprise a thermoplastic that is melted by the attachment mechanism 604 and which then sets to attach the end wall 1001 and peripheral wall 100B. In one such embodiment, the attachment mechanism 604 comprises a heating element or welding tip in place of the adhesive applicator 604 shown in Fig. 24. The attachment mechanism 604 could alternatively, or additionally, comprise a staple gun (not shown) or other such fastening mechanism.

[0193] In some embodiments, the device 601 is also configured to attach a second end wall (not shown) to an opposite second end of the peripheral wall 100B. For example, the robotic arm 602 may be configured to rotate the entire habitable structure 1000 after the first end wall 1001 has been attached to an end of the peripheral wall 100B, and to then attach the second end wall to the second end of the peripheral wall 100B. In another embodiment, the device 601 moves along a track (not shown) such that the device 601 is positioned at the second end of the peripheral wall 100B to attach the second end wall thereto. In a yet further embodiment (not shown), the apparatus 600 further comprises a second device (not shown) for enclosing the second end of the peripheral wall 100B with the second end wall.

[0194] In each of the above described embodiments, the apparatus 1, 101, 201, 301 forms a wall 100B of the hollow structure too that is substantially cylindrical. However, the wall 100B of the hollow structure too may instead have a different shape, for example, an oval, triangular, rectangular or square cross-section.

[0195] In each of the above described embodiments of apparatus 1, 101, 201, 301, the structure forming mechanism is configured such that the sheet material is conveyed along a helical path to form the wall 100B of the hollow structure too. It should be recognised that the term “helical” does not require that the sheet material travels at a constant pitch or radius about the conveyance axis and instead the pitch and / or radius may vary.

[0196] In some embodiments (not shown), the sheet 3A, 303A may be provided as a thin strip or ribbon of material. In other embodiments, the sheet material may be a wide sheet of material.

Claims

Claims1. An apparatus for forming a wall of a hollow structure for use in a space environment, the apparatus comprising: a supply mechanism configured to receive a supply of sheet material; and, a wall forming mechanism configured such that, in use, sheet material is fed from the supply mechanism to the wall forming mechanism, the wall forming mechanism comprising one or more guide members configured to guide the sheet material to advance about a conveyance axis and in an axial direction along the conveyance axis to form a wall of a hollow structure.

2. An apparatus according to claim 1, comprising a layer provision mechanism that is configured to provide a layer of material and, preferably, wherein the layer of material is provided on the interior of the wall.

3. An apparatus according to claim 2, wherein the layer of material is at least one of: a sealing layer, a thermally insulating layer, and / or a shielding layer.

4. An apparatus according to claim 2 or claim 3, wherein the layer of material comprises a flexible material and, preferably, wherein the layer of material comprises a bladder and, preferably, wherein the bladder is inflatable.

5. An apparatus according to any one of the preceding claims, wherein the apparatus is configured to receive a supply of a second sheet material, wherein the structure forming mechanism is configured such that, in use, the second sheet material is fed to the structure forming mechanism, and wherein the one or more guide members is configured to guide the second sheet material to advance about the conveyance axis and in the axial direction to form an additional layer of the wall of the hollow structure.

6. An apparatus according to any one of the preceding claims, wherein the sheet material has first and second edges, and wherein the one or more guide members are configured to guide the sheet material to advance about the conveyance axis and in the axial direction such that the first edge overlaps the second edge.

7. An apparatus according to any one of the preceding claims, wherein the one or more guide members are configured to guide the sheet material along a substantially helical path.

8. An apparatus according to any one of the preceding claims, wherein the apparatus comprises a joining mechanism that is configured to join a first portion of the sheet material to a second portion of the sheet material and, preferably, wherein the joining mechanism comprises a heater configured to heat the sheet material and, preferably, to inductively heat the sheet material and / or, wherein the joining mechanism is configured such that the join of the first and second portions subtends continuously about the conveyance axis to form a hermetic seal.

9. An apparatus according to any one of the preceding claims, wherein the or at least one of the guide members comprises a guide roller and / or wherein the or at least one of the guide members is adjustable to adjust the size of the wall of the hollow structure that is formed by the apparatus.

10. An apparatus according to any one of the preceding claims, wherein the hollow structure is a habitable structure.

11. An apparatus according to any one of the preceding claims, comprising a supply of sheet material received in the supply mechanism and / or wherein the sheet material comprises carbon fibre reinforced thermoplastic and / or wherein the supply mechanism is configured to receive a roll of sheet material.

12. An apparatus for forming a hollow space structure, the apparatus comprising: an apparatus for forming a wall of a hollow structure according to any one of claims 1 to 11; and, a device for enclosing an end of the wall.

13. A method of forming a wall of a hollow structure for use in a space environment, the method comprising: feeding sheet material from a supply of sheet material and guiding the sheet material to advance about a conveyance axis and in an axial direction along the conveyance axis to form the wall of the hollow structure.14- A method of forming a hollow structure for a space environment, the method comprising providing an enclosed hollow chamber that is surrounded by a wall, wherein the wall is formed according to the method of claim 13.

15. A hollow structure formed according to the method of claim 14 and, preferably, wherein the hollow structure is a habitable structure.

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