Foamed Film Shell Element for Rapid Temporary Housing
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Solution Overview
Problem
Existing methods for constructing temporary housing structures are inefficient due to the need for bulky materials, heavy construction machinery, and time-consuming assembly processes, especially in disaster scenarios where rapid setup is necessary without access to such resources.
Innovation Solution
A shell element composed of a thin film integrated with a layered foamed material portion, where the foamed material is adhered to one side of the thin film, allowing for tensional force on the film and compressional force on the foamed material, enabling lightweight, quick assembly of structures with high insulation performance and resistance to external forces without requiring large-scale machinery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If blocks made of foamed resin are used to construct structures, then structures with big span can be formed without pre-stressed concrete plates, but transportation vehicles are necessary to transport blocks and construction machinery is needed for lining up blocks, making the process time-consuming
Solution Approach 1:
The shell element is divided into multiple layers (first layer, second layer, third layer) with different functions. The first layer provides structural strength, the second layer provides insulation, and the third layer protects against external forces. This segmentation allows each layer to be optimized for its specific function while being manufactured as an integrated unit, eliminating the need for time-consuming on-site assembly of multiple separate components.
Solution Approach 2:
The shell element uses composite material structure combining multiple layers with different properties. The first layer uses high-strength material for structural integrity, the second layer uses insulating material for thermal protection, and the third layer uses durable material for external protection. This composite approach achieves both structural strength and functional performance in a single integrated component that can be transported and installed quickly without requiring construction machinery.
2Weight of moving object
If glass-fiber-reinforced plastic material is used for partition walls, then lightweight structures can be constructed in short time with good exterior appearance and heat/sound insulation, but transportation vehicles are necessary and frame formation is time-consuming
Solution Approach 1:
The shell element employs a flexible thin-film structure that can be easily transported and deployed. The thin film layers are lightweight yet provide sufficient structural integrity when properly configured. This eliminates the need for complex rigid frame structures and heavy transportation, while still providing the required insulation and aesthetic properties through the multi-layer configuration.
Solution Approach 2:
The invention extracts and eliminates the complex frame structure from the partition wall design. Instead of requiring separate frames and panels, the shell element integrates all structural and functional properties into a single panel unit that can be directly installed without frame assembly, significantly reducing device complexity and installation time.
3Stability of the object's composition
If adhesive and screws are used to connect blocks, then neighboring blocks can be integrated, but the work to apply adhesive and compress blocks is time-consuming
Solution Approach 1:
The shell element merges multiple blocks into a single integrated unit during manufacturing. The multi-layer structure is produced as one continuous component with internal bonding already established, eliminating the need for time-consuming on-site operations of applying adhesive and compressing separate blocks. The integrated unit maintains structural stability while enabling rapid deployment.
Solution Approach 2:
The bonding and integration of multiple layers is performed in advance during the manufacturing process rather than during on-site assembly. The first, second, and third layers are pre-bonded together to form a complete shell element before transportation, so that no additional bonding operations are required during installation, significantly improving assembly speed while maintaining integration stability.
4Strength
If compressive band plates are used to compress blocks, then blocks can be integrated in connecting direction, but the work to compress blocks on construction site is time-consuming
Solution Approach 1:
The compressive forces and structural integrity are established in advance during the manufacturing process. The multi-layer shell element is produced with pre-applied compression and bonding, so that the structural strength is already achieved before the element leaves the factory. This eliminates the need for time-consuming compression operations using band plates or other devices during on-site assembly.
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
The solution allows for the rapid and efficient creation of lightweight, heat-insulated structures that can withstand external forces and are recyclable, suitable for temporary housing or advertising, without the need for heavy machinery, and can utilize external wind, temperature, or humidity without cracking or splitting.
Implementation Method 1
a foamed material portion (40) is formed by foaming and spraying a resin material on an internal side of the thin film (30)
Implementation Method 2
The thin film (30) permeates water vapor, and is preferably moisture-permeable waterproof sheet without permeating water
Implementation Method 3
utilize external wind, temperature, or humidity without cracking or splitting
Data Source
AI summary
[Summary]A shell element that can be formed simply and in a short time, a shell structure using the shell element, and a structure forming set that can form the shell element simply and in a short time are provided.Resin material is foamed on the inside of thin film, a foamed material portion with bubbles being mixed is in the state of being sandwiched by the thin film and a solid layer, and tensional stress is applied to the thin film and the solid layer and compressive stress is applied to the foamed material portion, thus the shell element is difficult to be cracked or split, and the shell structure is formed by the shell element. And, the shell structure forming set forms the shell structure easily.