Curvilinear Building Structures Using Inflatable Foam Forms
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Solution Overview
Problem
Existing methods for constructing curvilinear buildings face challenges such as high material and labor costs, reliance on skilled labor, and inefficiencies in material usage and transportation, while conventional rectangular structures are less energy-efficient and more costly to build and operate.
Innovation Solution
A system utilizing interconnected structural tubes and sandwich panels, where flexible membranes are saturated with a curable material that forms into solid foam upon curing, allowing for the creation of lightweight, insulating, and structurally sound curvilinear structures that can be easily transported and assembled with minimal on-site labor, reducing material waste and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional rectangular structures are used, then construction is simpler and more straightforward, but material usage increases by 22-58% and energy efficiency decreases
Solution Approach 1:
The patent applies curvilinear design principles by forming building structures with curved surfaces using inflatable forms. The inflatable membrane is inflated to create a three-dimensional curvilinear shape, which then serves as a mold for applying structural material. This curvature reduces material usage by 22-58% compared to rectangular structures while maintaining structural integrity through the aerodynamic efficiency of curved forms.
2Loss of substance
If curvilinear design is implemented, then material efficiency improves and energy savings increase, but construction complexity and skilled labor requirements increase
Solution Approach 1:
The inflatable form serves a dual function: it is both the structural support during construction and the mold for the final building shape. The form is inflated to the desired curvilinear configuration, structural material is applied directly to its surface, and then the form is deflated and removed, leaving the self-supporting curvilinear structure. This self-service approach eliminates the need for complex scaffolding and reduces skilled labor requirements.
Solution Approach 2:
The patent changes the physical state and properties of materials during construction. The structural material is applied in a pliable, uncured state to the inflatable form, allowing it to conform to the curved surface. Once applied, the material is cured or hardened in place, transforming from a flexible state to a rigid structural component. This parameter change enables complex curvilinear shapes to be manufactured with relative simplicity.
3Strength
If traditional curvilinear construction methods are used, then structural integrity is achieved, but transportation costs and labor expenses increase
Solution Approach 1:
The building structure is divided into multiple inflatable form segments that can be individually transported to the construction site. Each segment is inflated and positioned separately, then joined together to form the complete curvilinear structure. This segmentation allows the structural components to be transported in a compact, deflated state, significantly reducing transportation costs and material handling requirements while maintaining the integrity of the final assembled structure.
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 costs and time, enhances energy efficiency, and allows for innovative design options by leveraging the structural integrity of curvilinear forms, achieving substantial material and energy savings across the construction process.
Implementation Method 1
a lining connected to the inner surface of the membrane, wherein the lining contains a curable material that has formed into a solid foam material
Data Source
AI summary
A system and method for primarily erecting curvilinear buildings using a plurality of interconnected structural tubes/sandwich panels is provided. Fabricating structural tubing comprises: connecting a fibrous and flexible lining to an inner surface of a flexible outer membrane, wherein the lining is saturated in a curable material that forms into a solid foam material when cured; and curing the curable material. Fabricating a sandwich panel comprises: connecting a first fibrous and flexible lining to an inner surface of a first flexible outer membrane, wherein the first lining is saturated in a curable material that forms into a solid foam when cured; connecting a second fibrous and flexible lining to an inner surface of a second flexible outer membrane, wherein the second lining is saturated in a curable material that forms into a solid foam when cured; and curing the curable material of the first lining and second linings.