Airforming Constructive System Using Inflatable Molds
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Solution Overview
Problem
Traditional concrete formwork techniques are laborious and time-consuming, especially for forming complex or curved structures, which require additional materials and labor, making them expensive and difficult to produce.
Innovation Solution
The use of aluminum alloy fiber reinforced concrete and inflatable support molds to form structures, allowing for the creation of complex shapes with minimal human intervention by filling a mold with fluid structural material that hardens to form the structure, such as buildings or statues, using a system comprising inner and outer support molds with separator components and pressure valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional concrete formwork techniques are used to form complex or curved structures, then structural integrity can be maintained, but construction time and labor costs increase significantly
Solution Approach 1:
The patent uses inflatable support molds that can be inflated with air or fluid to create the desired structural shape. The molds are inflated to a predetermined pressure to maintain structural integrity during concrete pouring, then deflated and removed after curing. This pneumatic approach replaces traditional rigid formwork, significantly reducing construction time while maintaining structural quality.
Solution Approach 2:
The patent changes the physical state of the support mold from rigid (traditional formwork) to flexible inflatable (pneumatic/hydraulic). By controlling inflation pressure and using flexible materials, the system can adapt to complex geometries while maintaining the necessary structural support during concrete curing, thereby reducing construction time without compromising integrity.
2Strength
If traditional concrete formwork techniques are used for complex structures, then structural strength can be achieved, but material usage and cost increase
Solution Approach 1:
The patent employs thin-walled inflatable support molds made of flexible materials that can be inflated to the required pressure to provide structural support during concrete pouring. These thin-film molds use significantly less material compared to traditional rigid formwork while still maintaining structural strength through proper inflation pressure and material selection.
Solution Approach 2:
By changing from rigid formwork to inflatable molds, the patent reduces material consumption. The inflatable molds can be made from thin-walled flexible materials that, when pressurized, provide adequate support strength. This parameter change in material state and structure reduces both material usage and associated costs while maintaining structural integrity.
3Manufacturing precision
If traditional formwork methods are used for curved and complex structures, then geometric precision can be achieved, but manufacturing complexity and labor increase
Solution Approach 1:
The patent uses flexible inflatable molds that can be inflated to assume precise geometric shapes. The flexibility of the thin-film material allows the mold to conform to complex curved surfaces while maintaining geometric precision through controlled inflation. This eliminates the need for complex rigid formwork assemblies, reducing manufacturing complexity and labor requirements.
Solution Approach 2:
The patent transitions from static rigid formwork to dynamic inflatable molds. The molds can be inflated and deflated as needed, allowing for easy setup, adjustment, and removal. This dynamic approach simplifies the formwork system while maintaining geometric precision through controlled inflation pressure and mold design.
4Strength
If traditional concrete formwork is used for complex structures, then structural support can be provided, but labor requirements and costs increase
Solution Approach 1:
The patent replaces labor-intensive rigid formwork with automated inflatable molds that can be quickly inflated and positioned using pneumatic or hydraulic systems. The molds provide necessary structural support during concrete pouring through controlled inflation pressure, eliminating the need for extensive manual assembly and adjustment, thereby significantly improving construction efficiency and reducing labor requirements.
Solution Approach 2:
By changing from rigid to inflatable formwork, the patent transforms a labor-intensive process into a more automated and efficient operation. The inflatable molds can be rapidly deployed and adjusted by controlling inflation pressure, reducing the need for manual labor while maintaining adequate structural support during concrete curing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method significantly reduces construction time and labor costs, enabling the rapid formation of complex structures like buildings and statues in under 72 hours with reduced material usage, while maintaining structural integrity and allowing for varied geometries and surface textures.
Implementation Method 1
an inflatable support mold configured to be inflated with a fluid to a predetermined pressure to a predetermined shape
Implementation Method 2
the fluid structural material hardens to form the structure
Data Source
AI summary
A composite material structure can be constructed using an airforming process that includes filling the inflated support mold with a fluid structural material and allowing the fluid structural material to harden within the support mold. Additional steps can include inflating the support mold with a first fluid, forming fluid escape outlets in the support mold, and removing the support mold after allowing the fluid structural material to harden. The first fluid can be air, the support mold can be a fiberglass resin, and/or the fluid structural material can be a concrete composite material. Fluid can escape through the fluid escape outlets during the filling. The finished structure can include multiple structural components formed from a homogenous concrete composite material and having curved and non-planar geometries. The concrete composite material can include aluminum alloy fibers.