Net Layer Building Shell with Hardening for Rapid Construction
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Solution Overview
Problem
Conventional building construction methods are costly, time-consuming, and exclude many from home ownership and affordable office space due to high construction prices and rising rents, necessitating a more efficient and cost-effective approach using locally available materials.
Innovation Solution
A building method and structure that forms an exoskeleton using a net layer supported by necessary components, with a hardening layer to create self-supporting shells that can be modified on-site, allowing for rapid construction with indigenous materials, reducing material costs and construction time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional building construction methods are used, then structural strength and durability are achieved, but construction time and cost increase significantly
Solution Approach 1:
The patent employs a flexible net or fabric layer as a formwork that can be draped over supports to create building shells. This flexible membrane system eliminates the need for traditional rigid formwork and extensive framing, allowing rapid deployment and formation of structural envelopes. The net layer serves multiple functions including formwork, reinforcement, and potential finishing surface, significantly reducing construction time while maintaining structural integrity.
Solution Approach 2:
The invention combines the flexible net layer with concrete or other binding materials to create a composite shell structure. The net provides tensile strength and form retention, while the concrete provides compressive strength and durability. This composite approach achieves both speed of construction and structural performance, as the net-concrete combination cures rapidly and creates a monolithic shell that requires minimal additional framing or finishing.
2Reliability
If traditional wood framed walls with external sheathing are used, then structural stability is achieved, but material costs and construction complexity increase
Solution Approach 1:
The patent merges multiple traditional building components into a single integrated shell structure. The net layer, concrete shell, and structural envelope are combined into one monolithic element that provides both structural stability and weather protection. This eliminates the need for separate wood framing, sheathing, and finishing layers, reducing construction complexity while maintaining or enhancing structural reliability through the monolithic nature of the shell.
Solution Approach 2:
The net layer serves multiple functions simultaneously: it acts as formwork for the concrete, provides tensile reinforcement, defines the building's shape and architecture, and can serve as a finished or pre-finished surface. This multi-functionality reduces the number of separate components needed, simplifying the construction process while ensuring structural stability through the integrated design.
3Ease of manufacture
If conventional construction materials and methods are used, then building code compliance is achieved, but construction cost increases
Solution Approach 1:
The patent employs a disposable or single-use net layer that is draped over supports, used as formwork, and then remains embedded in the finished concrete shell. This eliminates the need to rent or purchase expensive traditional formwork systems that must be assembled and disassembled. The net is a low-cost material that serves its purpose and becomes part of the finished structure, reducing formwork costs and overall material expenses while maintaining code compliance through proper structural design.
Data Source
AI summary
A net layer (32) defines the shell (40) of a building, carried by any necessary supports. A hardening layer (34) is applied to fix the shape of the net layer (32) and to establish wall, roof, and floor. Optionally the shell is of sufficient strength to receive application of further layers in order to define an exoskeleton. Structures of roof sections include parallel-sided segments and converging-sided segments, with troughed or domed section shapes. Structures of walls include opposed shell sides (35), (78) and central filler layers (70), together defining an exoskeleton. Posts (72) can add additional structural capacities for supporting walls, roof and floor and can be formed integrally of net (32) and hardener (34).