US20250290306A1

US20250290306A1 - Efficient and Advanced Building Composite System (ABC) and Method

Info

Publication number: US20250290306A1
Application number: US18/602,535
Authority: US
Inventors: Tracy MCSHEERY
Original assignee: Individual
Current assignee: Individual
Priority date: 2024-03-12
Filing date: 2024-03-12
Publication date: 2025-09-18

Abstract

A composite building form and a related method of construction are disclosed. The building form comprises a first and second layer of basalt fibers with a layer of DCPD foam or inert material in between. Additionally, it incorporates a reactive surface that bonds to concrete. The forms can be pre-fabricated, with features that allow them to interlock, and be lightweight and easy to assemble, and can be shaped to suit various construction elements such as columns, beams, and frames. The method of use includes assembling the forms, pouring concrete, and allowing the concrete to cure, interlocking without the need for custom tools, and utilizing color-coded parts for ease of assembly and inspection. One embodiment also involves a waterjet or router for cutting the forms, prefabricated composite material for archival designs and a reactive material for faster and easier construction. Applications of the one embodiment might include facilitating construction efficiency, waste reduction, reinforcing structures, and minimizing requirements for heavy equipment. Innovation is further reflected in the advanced computer-aided design (CAD) and manufacturing (CAM), reinforced with strong basalt composite material, high-speed assembly of complex shapes and advanced form reusability strategies.

Description

BACKGROUND OF THE INVENTION

The construction industry needs technologically advanced, cost-effective and eco-friendly solutions to replace traditional modes of construction, which are often time-consuming, specialized labor-intensive, and especially with single use concrete forms, are not environmentally friendly. Long-standing methodologies of construction involve high costs, heavy machinery, and produce considerable waste. Moreover, traditional construction materials using steel reinforcement and concrete have significant carbon footprints and, in some cases, older methods may not meet today's stringent safety and sustainability standards as well as limit building life with failure of reinforcement steel.
Given these challenges, there has been a growing interest in composite materials. Composites offer unique advantages, especially when used in construction. They can be lighter, stronger, and more resilient compared to traditional materials. The present one embodiment offers numerous improvements and innovations over the existing methods in terms of material usage, assembly, time, labor, and overall efficiency in both construction and energy. Additionally, it focuses on reducing the carbon footprint and waste in landfills, thereby paving the way for sustainable construction practices.
One other significant aspect is the use of Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM), which have become integral parts of the construction industry. These technologies enable precise design and manufacturing processes, leading to efficient use of materials ‘made to order’ components using the design methodologies, resulting in a reduction in waste, and potential for mass production, thereby saving time and cost.

SUMMARY OF THE INVENTION

In a first aspect, a composite building form(s) and a related method of construction are disclosed. The building forms comprise a first and second layer of basalt fibers with a layer of DCPD foam or inert material in-between to make rigid structures. Additionally, it incorporates a reactive surface where desired that chemically bonds to concrete or geopolymers. The form can be prefabricated, lightweight, and easy to assemble, and can be shaped to suit various construction elements such as columns, beams, forms, and frames. Due to the manufacturing method, features for interlocking components, or joining with pipes, conduits, wiring, door frames, window frames and other systems, can be prefabricated before shipping to the building site. The method of use includes assembling the forms, pouring concrete, and allowing the concrete to cure in sturdy forms that are interlocking without the need for custom tools, welding, or other high-cost labor methods, and utilizing color-coded parts for ease of assembly and inspection. The one embodiment also involves a waterjet or router for cutting simple and complex features into the forms, modifying prefabricated composite material for archival designs and a reactive material for faster and easier bespoke construction. Leaving the forms in place both decreases the time of assembling, bracing, or locking into a structure the traditional concrete forms and removing them, cleaning them, and prepping them for repeated use, with a stay-in-place solution that increases the strength of the structure as well as reduces the steps and complexity of building structures and buildings. Applications of the one embodiment include facilitating construction efficiency, waste reduction, reinforcing structures, and minimizing requirements for heavy equipment. Innovation is further reflected in the advanced computer-aided design (CAD) and manufacturing (CAM) tools, reinforced with strong basalt composites, high-speed assembly of complex shapes and advanced form reusability strategies.
In another aspect, specific purpose composite building forms and structures are disclosed that are prefabricated, lightweight, and easy to assemble. The forms comprise a composite material including basalt, glass, carbon, or other fibers, and a reactive surface that bonds to concrete. The forms interlock without custom tools, welding, or other labor-intensive processes, and remain in place after pouring concrete, reinforcing the structure, and protecting it from natural disasters. In effect it becomes an additional exoskeleton to augment the more traditional rebar and beams, with the integration of both in the designs lowering the total build cost. Reducing or eliminating thousands of nails, screws, bolts, welds, and the onsite cutting and joining of rebar, boards, beams, and components can save hundreds or thousands of hours of labor, while decreasing the construction time. The forms are easily assembled using color-coded parts, diagrams, and digital twins, and can be cut to size and modified prior to delivery or on the job site, with a waterjet or router, allowing for easy fastening without complex or time-consuming fasteners. The composite building forms and structures offer advantages over traditional construction methods, including reduced construction time, cost, and waste. Binder materials such as concrete, mortar, and geopolymers will be used interchangeably and are not meant to restrict the use in any manner. While Basalt Fiber will be used predominantly, for succinctness, this material can be substituted with E-Glass, S-Glass, Carbon, or other fibers allowing flexibility and lower costs where the properties of Basalt are not needed. ABC would offer a resilient construction with high structural strength, wind, and impact resistance. The inert nature of basalt and other fibers improves the integrity against fire and flooding. The use of composite materials in construction increases the strength of the building and thereby reduces the amount of cement used in construction by reducing the CO2 emission of a structure of a given structural strength.
In summary, this novel Advanced Building Composite System (ABC) form and its assembly method provide a sustainable and more efficient alternative to traditional construction methods, thus meeting the industry's need for more eco-friendly, efficient, and cost-effective solutions.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1-31 show exemplary structures formed with the composite forms.

FIG. 32 shows an exemplary flowchart of a process to form composite building forms and structures that are prefabricated, lightweight, and easy to assemble.

DETAILED DESCRIPTION OF THE INVENTION

In the following paragraphs, the present invention will be described in detail by way of example with reference to the attached drawings. Throughout this description, the preferred embodiment and examples shown should be considered as exemplars, rather than as limitations on the present invention. As used herein, the “present invention” refers to any one of the embodiments of the invention described herein, and any equivalents. Furthermore, reference to various feature(s) of the “present invention” throughout this document does not mean that all claimed embodiments or methods must include the referenced feature(s).
Thus, for example, it will be appreciated by those of ordinary skill in the art that the diagrams, schematics, illustrations, and such as represent conceptual views or processes illustrating systems and methods embodying this invention. The functions of the various elements shown in the figures may be provided through the use of dedicated design software. Similarly, any interlocking features shown in the figures are conceptual only. Their function may be carried out through the operation of interlocking fasteners incorporated into the form, versus the more common screws, nails, bolts and other fasteners and welds that are used to join building components, the particular technique being selectable by the entity implementing this invention. Those of ordinary skill in the art further understand that the exemplary hardware, software, processes, methods, and/or operating systems described herein are for illustrative purposes and, thus, are not intended to be limited to any particular named manufacturer.
FIG. 32 shows an exemplary flowchart of a process to form composite building forms and structures that are prefabricated, lightweight, and easy to assemble. This innovation describes a composite building form that is specifically designed for construction applications. The structure comprises a first layer of basalt fibers which provides significant strength and durability. Basalt fibers are known for their superior mechanical properties, thermal resistance, and sound absorption properties. Basalt has low to zero corrosion, reducing or eliminating the problem of steel mesh, steel I-beams, and steel fasteners and decking rusting, or corroding before being covered with a protective alkali layer of concrete. Using this composite material in the form of basalt, glass, or carbon fibers significantly enhances the strength and stiffness of the built structure. In general basalt fibers tend to be on the order of three to four times the tensile strength for a given cross section, or one third to one tenth the weight for a given volume of a steel part, since the binder does not contribute to the strength appreciably. Lower weight reduces shipping and handling costs, as well as allowing for more complex shapes than easily fabricated out of steel.
The composite materials are prefabricated to the building design and shipped to the building location ready to assemble. If a new base shape is needed, a mold or form can be designed and fabricated using Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM) tools allowing hundreds of semi-custom parts to be rapidly created. Precision fabrication in a factory, mass production, inspection, quality control, and advanced assembly techniques reduce the number of steps required. Onsite assembly with lightweight forms that can be hand carried, and reduced fabrication, cutting, joining, screwing, nailing, and welding, greatly reduce the time to fabricate a large building.
The Basalt Composite Forms are enhanced in function to increase system strength with reactive surface or pozzolan bound to the basalt fiber forms, such as clinker or calcium carbonate which reacts with the cement in the concrete or geopolymer to form chemical bonds to the concrete binding the concrete to the surface of the forms. Materials that might react with moisture would quickly set and become passive. Mechanical methods such as the commonly used grit, makes the surface rough and does not actually bond with the concrete enhancing the pullout strength but to a lesser extent. Seasonal and temperature cycling can break these loose mechanical bonds so surface area is critical to providing more grip. For earthquakes, wind load, seasonal shifting, and temperature cycling, the increased strength of this system can dramatically improve structure and building strength and lifetimes.
Similar to insulated concrete forms, which use expanded polystyrene and snap together, and have plastic spacers allowing rebar to be placed, these Composite Forms are designed and fabricated to reduce assembly time and remain in place. Unlike Insulated Concrete Forms, which have almost no tensile strength and the foam is on the order of 30 PSI compressive strength and similar tensile strength, the described forms have thousands of PSI tensile Strength (basalt fiber tends to 400 Ksi or 3 Gpa tensile strength) and thousands of PSI compressive Strength.
ABC Forms reinforce the structure and since they remain in place, the structure is further protected from Earthquakes, Storms, Weather, Fire, and other natural disasters. Unlike steel, Basalt fiber as well as glass and carbon fiber, have superior strength characteristics at flame temperatures, and can be coated with intumescent paints to further protect the outer surfaces. Leveraging the strength of the ABC materials, the composites are designed to easily fit and lock together and cannot corrode. At approximately eight times the specific strength of steel, they can be lightweight, and easily carried by one or two people and set into place without cranes.
With color coded parts and digital twin diagrams that can be downloaded to Phones, Tablets and shown in Augmented Reality in place at the construction site, the ease of use, and ease of inspection will allow complex buildings to be rapidly assembled faster and more accurately, with less waste and labor.
Because the complex shapes can be waterjet cut starting with the flat, rectangular, cylindrical and contoured primary shapes, and the DCPD bonds to itself well, allowing additional features to be added for snaps, clamps and other complex shapes, the system can be hundreds of times faster to assemble, making the construction faster. In effect it provides the strength of composites with the complexity of injection molded parts and components.
Equally important the parts are made to tight tolerances in a factory setting, allowing huge savings versus constructing via cutting, welding, grinding, and sawing on the job site restricted by weather and environment.
Additionally due to the Computer Aided Design and Computer Aided Manufacturing being synergistic with the Architectural designs, less material is wasted, reducing carbon footprint and waste in landfills.
FIG. 1-31 shows exemplary structures formed with the composite forms.
FIG. 1 , outlines the general process for rapid manufacturing process of composite forms to create structures and buildings using prefabricated stay in place forms. The structural panels are laminations of composites such as 1002, where desired bound together using a foam such as 1040, sandwiched between two layers of composites. One or both of the exposed sides may be coated as desired with a pozzolan coating to create a chemical and mechanical bond with the cement or geopolymer binder when it is poured, creating a monolithic structure when the binder is cured.
FIG. 2 , clarifies that the foam layer 1040 is independent and bound to the composites panels 1002 so that they mechanically join together and become a stiff structure, but due to the thickness and structure of the foam add mechanical, acoustic and insulative properties of 1040, to the strength in tension of 1002, and the combined properties are synergistic.
FIG. 3 , demonstrates how in the before illustration, the composites are a simple construct of one or more composite sheets 1002 and where advantageous, a spacer material, 1040 (not shown). An exterior Pozzolan coating can be applied to one or both exteriors to allow chemical and mechanical adhesion to the concrete or geopolymer binder.
FIG. 4 , demonstrates how using a water jet cutter, routing table or other mechanism, the simple panel from FIG. 4 , can have added features to improve the function by allowing integration of other objects at known positions, precisely located due to their manufacture when possible in a factory setting as opposed to on a construction site. These features can be standardized, or customer driven for bespoke purposes given sufficient quantities.
FIG. 5 , demonstrates the design of spacing panels, 1004, which have synergistic features to the panels 1002 (not shown for clarity) and to allow integration of reinforcement bar 1012 (not shown for clarity), piping and conduits and the flow of concrete to allow creation of a monolithic unit. The surfaces of 1004 can if desired be coated with a Pozzolan as described above to increase their strength in the binder and prevent them from creating stress concentration points for tensile or sheer stress. The ability to snap into place spacers such as 1006 to support reinforcement bar 1012 (not shown for clarity), without special tools or complex mechanisms lends itself to rapid assembly by means to fitting the features of 1004 into slots prefabricated in 1002 (not shown for clarity) and locking them into place by means of locking bar 1008, which has an action force 90 degrees to the gravitational load of the concrete, as well as 90 degrees to the pressure or bursting load of the uncured concrete. While the concrete is curing this resists deformation of the panels 1002, by distributing the forces evenly. The lockbar 1008 can be inserted into place and then retained from vertical movement which could cause failure by tab 1010, which acting 90 degrees to the force vectors applied to the lockbar 1008, requires minimal forces to insert and retain the assembly.
FIG. 6 , further demonstrates how the lockbar 1008 will slide over and down on the features of spacer panels 1004, having been inserted in panel 1002, and then be restrained by tab 1010, while spacer 1006 is used to retain reinforcement bar 1012, both providing desired mechanical spacing and allowing rapid construction of rebar cages. While the features of spacer 1004 are shown large for ease of viewing in practice they would be minimized to allow maximum exposure of concrete and ease of pouring concrete without impacting flow or creating voids.
FIG. 7 , demonstrates how horizontal spacers 1014 provide similar function to vertical spacers 1006, but additionally provide support for column form 1030 (not shown for clarity). Spacer 1014 is locked into place aligning with panel 1002, with horizontal lockbar 1034 and tab 1010, again making the assembly quick and simple without relying on welding, wire ties of heavy rebar and other common current practices which drive up time and labor costs.
FIG. 8 , demonstrates how Ring Spacer Inner 1020 and Ring Spacer Outer 1016, or 1026, or ring spacer 1022 which locks into spacer panel 1014, and when desired to make a column style rebar cage can incorporate at will ring spacers are concentric with horizontal spacer 1014 to provide transverse reinforcement and allow ease of construction of column rebar cages by simply inserting ribbon bar 1012 (not shown for clarity) at desired intervals, and continuing this process up as many floors as needed. Since when made with lightweight composites, ribbon bar 1012 (not shown for clarity) can be hundreds of feet or meters long, this facilitates much stronger columns and structures than possible using traditional steel rebar that would weigh four to tens times as much and would be unwieldy in such lengths. While steel rebar can be wound and made to equivalent lengths, it would be difficult to assemble multiple floors without the vertical rebar getting in the way of assembling individual floors.
FIG. 9 , shows how a vertical rebar cage as indicated for columns is integrated with horizontal spacer 1014 by snapping together Ring Spacer inner 1020 and Ring Spacer Outer 1022 to both provide horizontal rigidity to the column rebar cage, usually provided by a circularly bent steel rebar for transverse reinforcement in industry welded or tie wrapped in place, as well as easy spacing of the reinforcement bar 1012 (not shown for clarity), at specified intervals.
FIG. 10 , clarifies column rebar cage assembly for longer segments, now showing how reinforcement bar 1012 is inserted into Ring Spacers 1016, and ring spacers 1018, 1020 and 1022 and 1026 which have similar radial spacing but vary in diameter to allow multiple layers of rebar cages, at desired intervals providing the desired vertical and symmetrical spacing of the column rebar cage. This allows joining rebar between floors in columns with the desired development length, or the distance in concrete to provide sufficient pull-out strength. Ring Spacer 2018 has additional features to anchor cables, conduits, pipes or other features that might be desirable to embed in columns.
FIG. 11 , shows how a column rebar cage is integrated into the forms 1002, and locked into place with horizontal spacer 1014, while the two panels 1002 are locked together with lockbars 1008, along with the vertical spacers 1004, having inserts 1006 binding ribbon rebar 1012 (not shown for clarity). The panels 1028 are attached (from the inside but shown exterior for clarity) to panels 1002 to prevent concrete from flowing out during pouring.
FIG. 12 , shows how a tube 1030 made out of composite materials is fabricated performing the same function as a cardboard tube often used in industry or a steel form often used for larger columns, but remaining in place after the concrete is poured to enhance column and building strength. With the pozzolan coating on the interior and the composite jacket on the exterior of the column, this provides exceptional strength to the column as well as stiffness, enhancing the moment as the tensile strength of the composite is applied at the maximum diameter. This is in contrast to the aforementioned cardboard tube which is most often removed as it provides no structural value, or the steel column forms, which are expensive and provide limited additional strength if they were left in place. The addition of a composite exoskeleton is proven in earthquake retrofits and other applications but is heretofore considered too complex and expensive to be integrated into the building system.
FIG. 13 , demonstrates the after structure of 1030, when appropriate features are created with a water jet cutter, router or other mechanism to provide precise features to integrate into the structure. Since this is a computer aided manufacturing process that can be done rapidly and automatically, the additional cost of these complex features is minimal, while the value of being able to lock into place with a simple rotation the column form of 1030 provides rapid assembly of an otherwise complex structure.
FIG. 14 , exemplifies how column form 1030 is lowered over reinforcement bar cage made up of ribbon reinforcement bars 1012 and spacer ring inner 1020, and then after inserting into appropriate slots fabricated in horizontal spacer 1014, rotates to lock into place for vertical alignment and positioning. Counter rotation is prevented by insertion of tab 1010 (not shown for clarity) which simply slides into a slot demonstrating proper alignment between column form 1024 and horizontal spacer 1014. It should be noted that the mechanism of color contrast between tabs 1010 and the other forms and spacers makes rapid visual inspection and confirmation of assembly and alignment straightforward despite the complexity of the assembly.
FIG. 15 , demonstrates column cap 1032 which is fabricated to allow precise positioning of beam forms 1036 (not shown for clarity), on top of column form 1030, and allow integration with floor decking 1050 (not shown for clarity). Depending on the position of the column in the structure the column cap can have two 90-degree slots cut out for corners, or three slots when in the middle of a wall section, or four slots for columns in the middle of the building or structure. The vertical rebar cages can be extended indefinitely with Spacer rings 1026, and 1016, and spliced with additional column rebar cages with Spacer Ring 1020 if needed to provide appropriate development length.
FIG. 16 , demonstrates how reinforcement bars 1012 with spacer rings 1020 and 1016, can be added at desired intervals to create the engineered development length required to integrate the floor or beam structure with the vertical columns. By simply varying the diameters of spacer rings 1016, 1020 and 1022, and 1024, they can be concentric to other rebar cage diameters, and quickly and easily allow integration of otherwise complex rebar assemblies. Ring Spacer 1026 provides additional restraint joining the pieces of the interior or exterior reinforcement bar 1012 with a spacer ring assembly 1020 and 1022. It should be noted that while the spacing in the drawings seems tight, in most buildings, freeways, and structures, the spacing between the reinforcement bar would be more than wide enough to reach in and snap the reinforcement bar 1012 and spacer rings 1020 and 1022 in place by hand.
FIG. 17 , demonstrates how beam form 1036 is integrated with reinforcement bar beam insert holder 1038 and beam insert lock 1042 to allow a horizontal rebar cage to be assembled quickly inside beams, with the flexibility of the bar allowing these pieces to be snapped into place. For ease of visualization the scale of the features of reinforcement bar spacers 1038 and 1042 have been exaggerated, when in use, they would be minimal to allow maximum flow of concrete. The interior of beam form 1036 would have a pozzolan coating to increase the pullout strength/adherence to concrete, and provide similar function to a steel I-beam, but with a composite structure being much lighter weight, and both protect the concrete and increase the moment of the beam with the exoskeleton function providing additional strength, fire resistance and being corrosion resistant making the building much safer from earthquakes, fire and flood. By forming beam form 1036 with integrated slots for precise spacing of reinforcement bar spacers 1038 and 1042, the creation of an integrated reinforcement system with no special tools and decreased time is facilitated.
FIG. 18 , demonstrates how beam forms 1036 can be tapered and joined in one embodiment with the system of column form 1030, being capped with column cap 1032, and spacers 1038 and 1042 being used to properly align a rebar cage of horizontal reinforcement bar 1012, integrated with vertical rebar segments 1012, using ring spacers 1024/1026. It can be seen how a second column can be assembled in a similar manner on top of this assembly, allowing the system to create multi-storied structures.
FIG. 19 , demonstrates how the pour stops 1044, and later floor decking, 1050 (not shown for clarity) are then integrated into the beam forms 1036, and the column cap 1032. Downward pressure which can be applied by the user snaps all these features into place, leveraging the precision available when manufactured in a factory setting. The loads applied by the pouring of concrete serve to hold the components in place rather than force them apart. The embedded features of Pour Stop Rebar Holder 1046, and Pour Stop Floor Decking Join 1048 integrate the floor with the walls and columns. Section A-A is identified for profile demonstrated in FIG. 20 .
FIG. 20 , demonstrates ribbon reinforcement bar 1012 integrated into the column with the desired development length to provide the code required pull out strength connecting the beams to the columns. As can be seen, the different radius allowed by Ring Spacers (not shown for clarity) allows concentric placement of an additional column rebar cage when indicated for additional floors.
FIG. 21 , provides a profile view to better illustrate the features of Pour Stop 1044, with the integrated rebar spacers 1046, which can also be used to hold in place cables, pipes and conduits if desired, aligned and registered with Column Cap 1032 on top of Column Form 1030.
FIG. 22 , now demonstrates how Pour Stop 1044 is attached to Beam Form 1036 by simply sliding into place. This will be prevented from moving inward by attaching Floor Decking 1050 which may be attached to Pour Stop 1044 via Pour Stop Join 1048 (shown detached to emphasize alignment features). The Floor Decking 1050 can be connected simply by downward force applied locking the alignment features together without need of special tools. Again by providing registration features that move interlocking features into place at ninety degrees to the loads and expected forces, we are able to create complex structures without traditional tools, welds, nuts and bolts and enhance performance while reducing time and materials.
FIG. 23 , shows how two Floor Decking sections may be joined together, with the same downward force applied locking them into place. Additionally Floor Decking Chairs 1052 are shown, which are aligned with features in Pour Stop Rebar Holder 1046 (not shown for clarity) so that the Reinforcement Mesh 1056 (not shown for clarity) can snap into place.
FIG. 24 Gives additional perspectives of the joining of multiple Floor Decking 1050 sections.
FIG. 25 demonstrates the integration of Floor Decking 1050 sections into Pour Stop 1044 via Pour Stop Join 1048, which is in turn locked into place with Beam Form 1036.
FIG. 26 provides perspective of the alignment of Floor Decking Chairs 1052 provides additional locking features to create a secure assembly when the concrete is poured and the assembly of Floor Decking 1050 into Pour Stop Join 1048, by which action locks Pour Stop 1044 into Beam Form 1036.
FIG. 27 , demonstrates how additional security from an event that might cause upward force disengaging the assembly can be prevented by inserting Floor Decking Lock 1054 into a slot in Floor Decking 1050 along Section B-B.
FIG. 28 shows Section B-B and how the Floor Decking lock 1054 secures Floor Decking 1050 in place with Pour Stop Floor Decking Join 1048, and securing Pour Stop 1044 to Beam Form 1036, preventing accidental release by a vertical action. Note the bright colors differentiating Floor Decking lock 1054 from Floor Decking 1050 allows easy visual inspection that required fasteners are in place before work is concluded.
FIG. 29 , provides additional perspective of the assembly of Pour Stop 1044 and Floor Decking 1050 showing the Floor Decking Locks 1054 in place and provides additional perspective of how the Pour Stop Rebar Holders 1046 are aligned with the Floor Decking Chairs 1052.
FIG. 30 , now combines Reinforcement Mesh 1056 with the Floor Decking chairs 1052 and the Pour Stop Rebar Holders 1046, so that when concrete is poured, all of these features are set in concrete. The expectation is that proper setup will allow rapid consecutive pours of concrete increasing the strength of the building.
FIG. 31 provides an integrated system perspective with the modular nature of the building components, now visible which despite the mechanical complexity of the systems, due to the advanced manufacturing capabilities can dramatically decrease time and labor as well as provide enhanced strength.
FIG. 32 shows an exemplary flowchart of a process to form composite building forms and structures that are prefabricated, lightweight, and easy to assemble. It is expected that the process described will decrease construction times by months, allowing the savings of labor and materials, and resulting in stronger, safer buildings.
I-beams, columns, and other mechanical structures get their strength from their geometric shape or moment, as well as the material properties. Increasing the moment or stiffness of the forms where desired involves a layer of dicyclopentadiene (DCPD) foam or other inert material. This layer is strategically disposed in between the first and second layer of basalt fiber cloth or fabric. The DCPD foam additionally functions as an effective thermal insulator and serves to improve the resistance of the resultant structure against sound, impacts, vibrations and other potentially damaging forces. Furthermore, by using an inert material, this layer also contributes towards minimizing possible chemical reactions that could degrade the structural integrity of the building form. The foam has a small contribution to the mechanical strength but becomes a foundation for the layers of composites and the system then has the mechanical strength, acoustic and thermal properties, that are desirable in buildings and structures.
Following the DCPD foam layer is the second layer of basalt fiber cloth or fabric. As in the case of the first layer, basalt fibers are used for their remarkable mechanical, thermal and sound absorption properties. This second layer is characteristically the same as the first layer of basalt fiber but carries an additional feature of having a reactive outer surface to bond with the concrete and anchor the form in place, versus the more common steel placements of beams, decking, and mesh, which are mechanically entrained, but don't bond with concrete. In some cases that reactive layer can be on both sides if desired.
Using this innovative composite building form in construction projects can result in structures that demonstrate improved mechanical strength, better thermal and acoustic insulation, and enhanced resistance to potentially harmful external influences. The layering structure and the addition of a reactive surface make it a superior alternative to conventional building materials.
In conclusion, this composite building forms and components made of two (or more) layers of basalt fiber cloth or fabric interspaced with a layer of DCPD foam or inert material, capped with a concrete-adhering reactive surface represents a significant breakthrough in building form technology. By intelligently combining materials in the ways described, this design promises not only enhanced structural performance but also an added contribution to sustainable construction practices by improving the durability and longevity of built structures.
The present one embodiment relates to a composite building or structural form particularly suitable for applications demanding high strength, lightweight structures with flexible design capabilities. This composite material not only offers superior physical properties in terms of structural strength and durability but also exceptional aesthetic flexibility, suitable for a variety of architectural and design applications, from building and structural components to furniture and artwork. Of unique importance, the composite material involves a layer composed of either basalt, glass, or carbon fibers, which are known for their remarkable tensile strength and low weight characteristics, enhancing the overall high performance of the composite.
This composite building forms if desired can be impressed in a molded surface texture and can be manufactured into the shape of a desired architectural element, such as wood, brick, stone or other shape, as is common in concrete textured forms, and synthetic siding but having mechanical fastening mechanisms integrated into the forms, eliminating the need for additional finishing or extensive shaping, making it particularly beneficial in the construction process. The design embodies simplicity and adaptability, allowing for multiple uses within one form. The material composition comprises of carefully selected combinations of composite materials primarily offering high tensile strength, rigidity, and durability. Further, its manufacturing process involves careful molding and layering techniques that contribute to the overall strength and structure of the final architectural elements.
Overall, this patent encapsulates an innovative composite building form meticulously crafted to adapt to diverse architectural expectations while ensuring efficient construction processes. It marks a significant contribution to the construction industry by revolutionizing the manufacturing and assembly of different architectural elements.
Lastly, the composite building form is designed to be easy to assemble. This assists in simplifying the construction process by only requiring basic skills and minimal tools, thus providing higher efficiency and cost savings. Each prefabricated component is designed to interlock with each other flawlessly, with many of the ‘lynch pin’ or wall-ties type of features commonly used in the construction industry, not having to be removed later or patched on curing of the concrete, providing a seamless combination resulting in a swift and straightforward assembly process. The gravitational load of the poured concrete is designed to be borne by the structure, and then once the concrete is cured, the structure is permanently locked into place. This easy-to-assemble attribute enhances the user experience by reducing the time, resources, and complexities associated with traditional building methods, while simultaneously promoting speed, efficiency, and productivity during the construction process. While the stay-in-place forms might seem to be more expensive, vis a vis wooden forms that can only be used once or twice, or steel and aluminum forms that can be reused many times, but have considerable setup and take down, and prep labor, because they reduce construction and labor time significantly, and increase the building strength, the net cost of the structure or building is lower than the traditional construction methods. Additionally, since the moment of the concrete/composite beam or column is improved by the strength of the reinforcement being at or near the surface, less concrete can be used for a given structural strength further reducing the costs and environmental impact. In some designs a considerable about of load is the concrete skin outside the rebar or I-beam that is meant to protect the steel underneath. The composite building form contributes to a more sustainable and efficient construction solution, meeting the escalating demand for environmentally friendly, cost-effective, and time-efficient building practices.
The present one embodiment is a composite construction or building form constituting at least one form for building structures. The form is composed of a specially designed composite material that combines basalt, glass, carbon, or other fibers as needed, to create a strong, durable form suitable for various building applications. One of the key advantages of using this composite building form compared to traditional materials is its extraordinary strength-to-weight ratio, making it a highly efficient and cost-effective choice for construction needs. Furthermore, this composite material offers high resistance to environmental stressors such as weather conditions, UV radiation, and corrosion, ensuring long-lasting performance and minimal maintenance requirements.
The composite building form provides an array of advantages over conventional building materials. Its high degree of durability and strength, coupled with its capacity to bond seamlessly with concrete, results in a revolutionary construction tool that substantially enhances the functionality and efficiency of building projects. Whether used in residential, commercial, or infrastructural developments, the composite building method proposed here addresses a critical need within the construction industry for a sustainable, simple-to-use, and highly effective building solution. The inventive composite building form is a significant milestone in the realm of construction materials and processes, taking a step forward in the direction of more advanced, efficient, and sustainable buildings. Thus, this one embodiment carries a vast potential for transforming the construction industry by introducing an advanced product that combines unprecedented durability, efficiency, and bonding capabilities.
In the first step of the method, it involves the assembling of a plurality of composite building forms. The forms can have any shape or size to fit the unique specifications of the building design. They are pre-fabricated and delivered to the construction site where they are arranged and assembled according to the architectural plan.
The next step involves the pouring of concrete into the assembled composite building forms. The type of concrete or geopolymer used can be chosen based on the specific requirements of the building such as strength, durability, and longevity. The concrete is typically mixed on-site or off-site and then transported to the construction location. The concrete mixture is then poured into the forms, making sure to fill all the corners and crevices to ensure a solid structure once it hardens.
Once the concrete is poured into the building forms, an important part of the method involves allowing the concrete to cure. The curing process is a chemical reaction where the concrete hardens and gains its strength. The length of the curing process can vary depending on the type of concrete used, the temperature of the environment and the humidity level, among other factors. The curing process is vital to the overall integrity of the finished building. Normally each section or floor is required to cure before the forms can be removed, causing multiple pours to be done over days or weeks. By having all the forms preassembled, the pours can be almost continuous, allowing for gelation of the concrete to keep from overflowing between floors, and not isolated by days or even weeks, allowing for much improved construction times, and greater system strength. In many types of high strength concrete, additional strength comes at the expense of longer cure times. By not having to remove the forms within 8 or 24 hours, these high performance concretes and geopolymers can be used, and due to their enhanced strength characteristics, less overall material can be used to complete the building or structure.
The method described in the present one embodiment stands to significantly simplify the construction process by reducing the need for extensive manual labor. It may also limit waste produced during construction as the forms can be reused or repurposed. Moreover, the use of composite building forms with greater strength and rapid assembly, may provide greater flexibility in the building design process, enabling the creation of structures with unique shapes and layouts that may not be achievable using traditional construction methods.
In conclusion, the method of constructing a building, consisting of assembling a plurality of composite building forms, pouring concrete into the forms, and allowing the concrete to cure, delivers a novel approach to building construction. It is envisaged implementing this method could provide considerable advantages for the construction industry, including enhanced structure stability, greater design versatility, reduced construction times, and cost savings.
The present one embodiment relates to a method for interlocking forms without the use of custom tools, thus enhancing the efficiency and cost-effectiveness of construction processes. These forms, once interlocked, remain in place even after the pouring of concrete which further reinforces the overall structural integrity and provides protection. This revolutionary approach to assembly not only reduces or obviates the need for specialized tools, but also removes dependencies on highly skilled labor, thereby speeding up the construction process and minimizing the margin of human error.
Furthermore, to further streamline the assembly procedure and minimize the potential for misunderstandings or incorrect arrangements, the parts of the forms are color-coded. The color codes could correspond to specific functions, spots or positions in the form arrangement, making it easy for the construction workers to connect the corresponding parts together accurately. This intuitive coding mechanism ensures a seamless assembly process, reduces mistakes, and enhances overall productivity and work efficiency. Further, the color-coding technique used in the method provides visually perceptible guidance to aid in the accurate construction and lends itself to human or computer vision inspection of the composite building forms, which potentially reduces errors, time, and costs associated with the construction process.
In another aspect of the one embodiment, diagrams or digital twins can also be utilized to guide the assembly process. These digital twins are a virtual replica of the physical components and can provide a dynamic, in-depth representation of the form. They can be manipulated and viewed from any angle, ensuring that every detail can be clearly seen and understood. This allows for detailed planning and visualization of the form assembly in advance, enabling a more comprehensive understanding of how the forms interlock, how to pour concrete and how reinforcement and protection of the structure are to be effectuated. This not only allows planning and organizing which simplifies installation but also enhances precision, thus reducing potential risks and time wastage during the construction stage.
The core aspect of the one embodiment is a specially designed composite building form, which includes a variety of interlocking features. These features are specifically designed to allow the forms to be easily locked together, creating a sturdy and stable structure. This innovative design takes on a significantly straightforward approach that can be conveniently operated, even by inexperienced users. Each element of the composite building form comprises a series of projections and recessions functioning together to create a secure grip when locked with its counterpart. This unique interlocking system enables quick assembly of the forms, promoting efficient construction processes and reduced labor input.
The design focuses on user-friendly aspects which not only reduces the barrier of entry for construction but also implies potential cost savings for both materials and labor. The one embodiment propels a revolutionized solution for the construction industry, encouraging further technologies to embrace simplified designs that promote practicality without compromising structural integrity or safety.
As a significant enhancement in the construction industry, this one embodiment has wide applicability: it can be utilized in the construction of houses, commercial buildings, freeways, bridges, and more. By transforming a typically complex process into a comprehensible and straightforward system, this innovative method serves to streamline the construction phase. Additionally, it may lead to improvements in site safety, as the clear identification and differentiation of components could reduce risks associated with incorrect assembly or use of inappropriate elements. In summary, the color-coded composite building form construction method offers significant potential for improvement in terms of construction accuracy, efficiency, safety, and overall project cost reduction.
The one embodiment disclosed pertains to a method of manipulating composite building forms. These forms can be representative of a variety of structures such as walls, ceilings, or panels, and are integral components in the construction industry. More specifically, the one embodiment relates to a process of accurately cutting these composite structures to the required or preferred size, employing a waterjet or a router. The key aim behind this innovative method is to improve the precision and efficiency of the cutting process, vastly enhancing the overall structural construction process. This approach enables users to standardize and control the dimensions of the composite building forms effectively and consistently, which could potentially reduce material waste and labor time, and improve the final assembly quality.
In essence, the method comprises using a tool or router for cutting the composite building forms. The waterjet cutting is a powerful non-thermal process that utilizes a high-velocity stream of water, potentially combined with an abrasive substance, to erode or shear away the material, providing a smooth, clean cut without the heat-affected zones that can compromise the integrity of the composite material. On the other hand, the router is a high-speed rotary tool, typically utilizing a variety of bits suitable for different materials and cut types. A laser cutting tool uses a high-power laser to perform similar functions. The proposed method offers flexibility and adaptability as it can be implemented to cut a wide range of composite materials and forms, regardless of their thickness and hardness. It ensures a clean, smooth finish and precise dimension control.
A significant advantage of this method is the enhancement of precision and reduction in labor time. Traditional construction methods of cutting with saws and torch cutting can be time-consuming, labor-intensive, and may not provide consistent results. Furthermore, these traditional methods often introduce risks of material damage or deformation due to the application of excessive heat or mechanical stress. The application of waterjet or router cutting as outlined in this patent avoids these issues. This method allows for accurate, efficient, and swift production of composite building forms that meet specific size requirements. The outcome of this process is a reduction in waste, an increase in efficiency, and an overall high-quality finish. The one embodiment signals a step forward in the construction industry, paving the way for faster, more precise, and more efficient construction processes.
In the claimed method, the composite building forms which may be in the shape of walls, floor slabs, beams, columns, etc., serve as molds for concrete to be poured into, thus forming the constructed composite structure. The molds or forms used to fabricate these composite building structures can be made of various materials, including but not limited to, a combination of metal and plastic materials, which have been organized and assembled in a precise and predetermined design according to the construction requirements. Once the ABC basic form is shaped and cured, it can be cut with a tool such as a water jet cutter, and additional parts can be joined leveraging the DCPD surface to create a complicated structure. Finally, where the concrete is expected to come into contact with the form, the reactive surface can be applied to chemically as well as mechanically bond the form to the concrete. Unlike traditional concrete forms and molds, draft angles and features to guide the pouring of concrete, can be added to aid in the calculation of the expected volumes needed, and vibrate the concrete to compact in place can be modeled and planned. The geopolymer or concrete mixture, which includes cement, sand, aggregate, and water, is then poured into these forms. A vibration process may follow to ensure that the concrete integrates evenly into the composite forms, eliminating voids and air bubbles. After the concrete has cured to a predetermined level within the composite forms, they are removed, resulting in a robust composite building structure. The composite forms can either be disposable or designed for reuse, according to implementation preference or based on environmental considerations.
The one embodiment provides significant advantages over traditional construction methods. Firstly, it streamlines the construction process as wall, floor and column pieces can be created at a faster pace in a factory setting, reducing the labor-intensive on-site brick and mortar process. Secondly, the structural integrity of the finished building structure is increased due to the inherent characteristics of concrete and the precision from the uniform and predictable nature of composite form. Moreover, the method offers added durability because concrete, unlike wood or other constructs, is relatively impervious to fire, water, and termites. The one embodiment offers environmentally friendly benefits as the composite building forms can be created using recycled materials and are potentially reusable after the concrete has cured. Overall, this method provides an efficient, durable, and environmentally conscious approach to building construction.
The present one embodiment constitutes a material composition composed essentially of basalt, glass, carbon or other fibers, hereafter referred to as composite material. The fibers in question can include but not be limited to synthetic or natural fibers, inorganic or organic fibers, conductive or non-conductive fibers. Delineated in the claim is the composite material enhanced with a reactive surface facilitating adhesion towards concrete or similar structural substances.
This composition offers broad possibilities for application in various industrial settings, with particular focus on the construction and engineering sectors. The composite material proposed combines the robust, heat-resistant characteristics of elements like basalt and glass with the structural integrity and stiffness of carbon or equivalent fibers. This blend of materials results in a durable and versatile composite that can be used in a multiplicity of applications. For instance, it can serve as reinforcement in construction elements, improving their resistance properties against numerous strains such as bending, compression or stretching. Additionally, its reactive surface bolsters adhesion affinity towards concrete, ensuring a concrete-composite bond of unparalleled resilience.
The innovative aspect of the reactive surface allows the composite material to bond chemically with the concrete, therefore providing a significantly better longevity and enhanced tensile strength than traditional materials used in building construction like steel. This revolutionary technology can be rapidly implemented in a standard concrete-casting operation, indicating that the method is not only effective but practical and cost-efficient as well. Thus, the unique combination of key materials fortified with a reactive surface creates a composite substance that is hard-wearing, cost effective and highly adaptable to assorted uses, thereby promising notable advancement in construction methodologies and material engineering.
The one embodiment pertains to an interlocking assembly system designed to enhance the convenience, efficiency, and speed of assembly processes. Unlike traditional assembly methodologies, the one embodiment does not necessitate the use of custom tools, hence, improving accessibility and user experience. This innovative system encompasses a set of forms which are themselves designed to interlock, thereby allowing components to come together in a seamless manner.
The forms centrally involve a unique configuration composed of specifically devised form features. These features ensure that the forms have the capability to link together and lock into place effortlessly. By simplifying the ability to interlock, the one embodiment facilitates the ease of handling, usage, and assembly by individuals with varying skill sets. This interlocking aspect also enhances the structural integrity and safety of the assembled structure.
The one embodiment advances the technology pertaining to assembly systems by eliminating the need for custom tools. This significant advancement reduces the complexity of the assembly process and eliminates barriers for non-technical users. Thereby, the one embodiment introduces a system marked by universality and accessibility, which in turn have broad industrial applications. This innovative approach also reduces the cost and time associated with maintenance and repair, further enhancing the practicality and utility of this one embodiment. This one embodiment promotes sustainable and user-friendly assembly solutions that simplify processes and make construction accessible to a wider audience.
This innovative assembly method leverages sophisticated design principles to offer a system that not only simplifies assembly but does so without compromising on stability, safety, and utility. The universality of design enhances its applicability across various industries, making it a worthy contribution to the existing body of technology.
The present one embodiment relates to an improved method for constructing concrete structures more efficiently and with an enhanced level of reinforcement. This method involves maintaining the formwork in place after the pouring of concrete, thereby reinforcing the structure and providing ongoing protection.
In traditional concrete construction, forms are removed once the concrete has gained initial strength usually 8 to 24 hours after the concrete is poured, causing a time critical labor crunch. However, the central concept of this one embodiment is the retention of forms even after the concreting process. This ensures additional rigidity, especially in circumstances where the structure may be prone to high loads or environmental stressors. With the forms in place, the outer shell of the structure is more resilient and capable of withstanding significant wear and tear over time. The forms also provide a moisture barrier, protecting the concrete from moisture. Furthermore, the insulation benefit from forms in colder climates is notable as it helps in reducing the process of heat loss from the structure, thereby facilitating the curing process. The combination of less water intrusion, and barrier insulation will dramatically lower seasonal weather related concrete degradation.
The present one embodiment relates to an innovative method for the assembly of forms using color-coded parts, diagrams or digital twins as disclosed. The purpose of this inventive method is to enhance the quality of assembly and eliminate or minimize errors that may occur during the assembly process. This inventive color-coding method simplifies complex assembly procedures by easily identifying and differentiating various components.
In detail, the color-coded parts aspect of the one embodiment applies different colors to parts based on their characteristics, functionality, or sequence in the assembly process. Once color-coded, these parts can be easily identified, improving the speed, efficiency, and accuracy of the assembly process. This practical approach not only mitigates issues such as misplacement, incorrect ordering, or part mismatch issues, but can also provide immediate visual feedback to assembler facilitating effective quality control.
Furthermore, this inventive method integrates the use of diagrams or digital twins to provide visually accurate instructions and guidelines during the assembly process. The diagrams provide a clear, visually intuitive guide for completing the assembly process, while the digital twins provide a virtual representation of the physical form which can be manipulated in a digital space to further understand its assembly. By simulating the assembly at each step, the user can identify potential complications and mitigate them before they occur, optimizing the assembly process.
The enhanced and efficient method of assembling forms using color-coded parts, diagrams, or digital twins as claimed is not limited to a specific industry or product. Its application could extend to a wide range of industries such as construction, manufacturing, education, and more. It holds significant potential in revolutionizing traditional assembly processes, facilitating superior quality control, increased productivity, and reduced errors and rework. Ultimately this patent secures the rights to this game-changing assembly method that will shape the future of numerous sectors.
The disclosed one embodiment pertains to a uniquely designed apparatus, primarily composed of a specially engineered composite material, which has been compressed and formatted into a specific build design in accordance with the requirements of a construction project. The apparatus substantially provides an elevated level of flexibility and efficiency as it can be easily shipped to a designated building location for swift assembly, minimizing construction-related inconveniences.
This apparatus involves a construction methodology, making use of prefabricated structures. These structures comprised of composite material, that are designed, fabricated and readied off-site in manufacturing units. The prefabrication process involves the assembly of used materials into a composite, conforming to the building design in question. The use of composite material allows the apparatus to withstand diverse weather conditions while inferring structural integrity, thereby enhancing its suitability for varied building projects.
The composite material employed to fabricate the apparatus offers unmatched strength and durability, coupled with beneficial portability and lightweight qualities, easing the shipping process to the construction site. The process of selecting the composite material for the apparatus is based on stringent criteria including but not limited to resilience, adaptability, efficiency, longevity, and overall performance. The unique properties of the composite material, offer an added advantage of reduced construction waste and lesser dependency on traditionally heavy construction materials.
The prefabricated structure, tailored to the specifics of a building design, proves to be economical for several reasons. The use of the prefabricated structures can significantly decrease on-site construction time, reduce labour costs, and limit construction waste. It simplifies the construction process, aiding in efficient resource management, and provides a substantial reduction in the overall construction timeline. Besides, it contributes to sustaining environmental-friendly construction practices, notably reducing the emission of pollutants.
The apparatus can be easily shipped and assembled quickly at the building site. Once shipped to its final destination, this composite module can be swiftly assembled due to its pre-manufactured nature. This process avoids prolonged site disruption and allows the building to be ready for use in a shorter duration, contributing to higher productivity and cost-effectiveness.
The assemblage of the prefabricated structure ensures architectural precision since it adheres strictly to the preplanned building design. To ensure suitability for the intended application, the product is tested extensively during and after the manufacturing process. This includes load testing to confirm structural integrity and durability, and weather testing to ensure resistance against adverse weather conditions.
Overall, this one embodiment revolutionizes the construction industry by bringing in an efficient, economical, and eco-friendly mode of building homes, buildings, and other structures. The apparatus, made from composite materials and manufactured to the exact specifications of the building design, paves the way for enhanced collaboration between architects, engineers and builders. The result is a high-quality product that could transform the face of the construction process as we know it.
The present one embodiment relates to an apparatus composed of a novel composite material, notable for its unique combination of two or more constituent materials. The different materials that can be amalgamated to engineer this composite material, though not strictly limited to, predominantly include metals, polymers, and ceramics. The resultant composite material inherits the salient qualities of its constituent materials, thus demonstrating a versatility of attributes which makes it ideal for a wide range of applications. The one embodiment's focus on leveraging the advantageous properties of various materials not only enables a highly efficient and strong apparatus but also inspirits a revolution in the design and fabrication of equipment across diverse industries.
More specifically, the metals incorporated in the composite material provide a robust and durable matrix that imparts high strength and resistance to the finished product. These metals might involve elements from across the periodic table, or their alloys. The polymeric components contribute a unique blend of flexibility, lightweight nature, and resistance to corrosion, which enhances the overall durability and longevity of the apparatus. The polymers could consist of natural or synthetic formulations, with the choice guided by desired properties for the end-use of the material. Furthermore, the incorporation of ceramic materials adds a dimension of hardness, wear-resistance, and heat resistance to the composite, opening it up for usage under extreme conditions.
The production method for the composite material of this one embodiment involves varied techniques such as layering, blending, molding, and curing specifically tailored to the particular constituent materials. The strategic alignment and distribution of the different elements within the composite allow for a highly-dense, structured material that accentuates the desired material characteristics. Therefore, the one embodiment presents a versatile and sturdy apparatus with a wide scope of adaptability due to the incorporation of varying materials in its composition. In essence, this one embodiment epitomizes a significant breakthrough in material science technology, revolutionizing the creation of objects with amplified durable, resilient, and adaptable qualities.
The first feature of the one embodiment pertains to the incorporation of precision fabrication techniques. As opposed to the traditional method of materials production, this one embodiment employs a state-of-the-art factory setting which utilizes precise robotic operations for the creation of its composite material. The use of these innovative methods results in consistent, accurate production that ensures the uniformity of the assembly parts, decreasing potential errors during construction. This feature enhances the overall quality of the final product, assuring high-performance consistency throughout its lifespan and reducing possible complications as a result of human error during manual production.
The second distinct aspect of this one embodiment revolves around its unprecedented approach to mass production. By leveraging modern production techniques such as automation and artificial intelligence, the process becomes more efficient, yielding a higher quantity of output within a shorter time frame. This innovation disrupts the traditional mode of construction, reducing costs related to both time and manpower. Additionally, the course of action enables the design to be easily replicated scaling effectively while maintaining a consistent build quality. Thus, this patent presents a method that revolutionizes the building fabrication process, offering not just quality but also affordability.
The apparatus also includes a supply of cement. Cement or geopolymers are a key ingredient in the formation of concrete structures for it binds together the different constituents of the material, ensuring their structural integrity and rigidity. The cement utilized in the present one embodiment is selected for its superior adhesive properties and its resistance to environmental degradation, thereby increasing the longevity of the concrete structures built using the device.
To utilize the apparatus, the basalt composite forms are first prepared and set in the desired layout. Next, the cement is mixed with water to form a paste and aggregate is added. The concrete mix is then cast into the basalt composite forms, ensuring they bond well with the reactive surfaces of the forms. Once hardened, this forms the final concrete structure, crafted to perfection.
This one embodiment pertains to an advanced, innovative apparatus constructed from a unique basalt composite, a natural and reliable material obtained from volcanic rock. Furthermore, the one embodiment is specialized with the integration of reactive surfaces that are proficiently coated with a layer of nanoparticles, enhancing the performance and capabilities of the one embodiment dramatically. The application of nanoparticles delivers a multitude of advantages, such as chemical stability, high thermal conductivity, a level of inherent fire retardance, and an enhancement of surface strength and rigidity. This addition results in an extremely reliable, sturdy, and long-lasting apparatus that increases efficiency and productivity in a myriad of different applications and sectors.
In more detail, the nano-coating envelops the basalt composite forms entirely, improving the natural characteristics of the basalt composite and creating a protective barrier against various forms of damage. This layer of nanoparticles performs dual functions; while increasing the overall strength, it also shields the reactive surfaces, retaining the inherent properties and expanding the lifetime of the apparatus. This protective feature safeguards the reactive surfaces from abrasion, corrosion, excessive heat, and other potentially damaging factors, promoting a prolonged, disruption-free operational lifespan.
The present one embodiment in claim 23 pertains to an apparatus characterized by comprised basalt composite forms, which are in the shape of panels. The panels are made of basalt composite material, a distinctive and strong composite developed by combining basalt fibers with a polymer matrix. The composite material offers improved mechanical properties such as high tensile strength, enhanced durability, crushed stone resistance, and excellent thermal stability. The panel-shaped configuration contributes towards the optimal usage of the composite's physical and mechanical properties, boosting the overall efficiency while ensuring lightweight and versatile structures for various applications such as construction, manufacturing, and industrial settings.
The present one embodiment relates to an apparatus featuring basalt composite forms which are shaped as cylinders. This structural configuration affords many functional benefits and applications optimized for strength and durability. Basalt, derived from volcanic rock, provides unmatched performance properties including high tensile strength, resistance against wear and thermal breakdown, high dimensional stability, and low weight compared to conventional construction materials such as steel and concrete. By forming this composite into cylinders, increased structural integrity, more effective distribution of load, and improved resistance to environmental stressors are attained.
The design of cylindrical basalt composite can be leveraged across multiple industries and applications where strength and resilience are mandated. Potential applications include but are not limited to, core fractions of buildings and bridges, tunnel support systems, offshore drilling platforms, wind turbine blades, vehicle components, and even spacecraft structures. The cylindrical design distributes stress evenly both longitudinally and laterally, mitigating potential issues related to fatigue and failure under high loads. Furthermore, the cylindrical structure optimizes material use, minimizing waste and providing cost-effective manufacturing and implementation solutions.
The present one embodiment, as set forth, relates to an apparatus featuring interlocking basalt composite forms. The basalt composite forms are primarily composed of basalt fibres, which are derived from finely ground basalt rocks, oftentimes supplemented with a process helper like a binder to reinforce its structure and connectivity. As a naturally occurring volcanic rock, basalt is a valuable resource featuring superior physical properties such as heat and sound insulation, resistance to fire, high durability and impact resistance, making the composite forms ideal for a wide range of industrial applications.
The one embodiment pertains to a novel apparatus that notably features key advantages in the construction field, particularly in the deployment of reinforced concrete structures. Essentially, this one embodiment can be employed for holding and positioning reinforcing elements, widely known as rebar, within the composite forms utilized in the construction of such structures. Embodied within the structure of the one embodiment are spacers, strategically placed and designed with the specific intent of facilitating optimal rebar placement within these composite forms. In essence, the apparatus functions as a significantly improved method and interface for managing rebar in the construction process, creating reinforced concrete structures that are markedly elevated in both quality and durability.
At its core, this apparatus is meticulously designed to integrate spacers that not only hold the rebars but also set them at the correct spacings. In this manner, concrete is poured around these rebars, thereby creating a reinforcing cage or grid within the concrete structure wherein these rebars contribute substantially to the strength and stability of the structure. The advanced art of this apparatus is reflected in its focus on precise and effective rebar placement, enabling less cumbersome placement and adjustment of rebars-a critical advantage in the labor-intensive, safety-sensitive field of construction.
The innovative design essentially transforms the conventional procedure of rebar placement into a more streamlined and efficient process. The incorporation of these ingenious spacers enhances the balance and stability of the rebar, simultaneously providing the means to withstand substantial loads and pressures during the setting and curing of the concrete. In offering an efficient way to maintain the necessary spatial arrangement for rebars, the apparatus inevitably contributes to the longevity and resilience of the resulting concrete structures, revolutionizing the construction industry through superior design. Thus, the novel apparatus is an invaluable addition to the arsenal of tools available for use in construction ventures, bringing about a considerable enhancement in productivity and precision in creating reinforced concrete structures.
The disclosed one embodiment pertains to a versatile apparatus that comprises customizable composite forms able to confer advantages to various construction purposes. The customization feature of the composite forms allows the one embodiment to be versatile in its application, thereby accommodating a wide variety of construction needs. These forms, part of the claim 45, can be molded or restructured into different sizes and shapes depending on the specific requirements of a construction project. They can be produced following particular configurations, from simple geometric shapes to complex layouts, thereby catering to diverse design needs. This dexterity of reshaping and resizing grants builders and designers the flexibility to modify the composite forms on-site or off-site, facilitating seamless integration into the build environment.
The composite forms, unlike the rigid nature of traditional construction materials, bestow the construction industry with an innovative tool to realize complex structures. Manufactured from advanced composite materials, they exhibit superior strength despite being lightweight, which allows for cost-effective transportation and storage. Also, the composite materials are resistant to environmental factors like heat, moisture, and impact. They boast of an extended lifespan, which makes them an ideal choice for construction needs, particularly in harsh environments.
The present one embodiment as described within pertains to an improved apparatus equipped with interlocking features on the composite forms in order to provide enhanced stability and structural integrity. The one embodiment embodies a novel, optimized design that affords exceptional robustness and improved operational efficiency. The interlocking features provided on the composite forms are specifically adapted to align and fit impeccably with each other, creating a sturdier structure. This not only endows the apparatus with better endurance against various operational forces and stresses, but it also minimizes damage or wear and tear caused by repeated use or during event of shocks or impacts. Furthermore, the interlocking feature reduces the risk of any potential distortion or mangling of the structure, thereby ensuring that the apparatus maintains its functional efficiency throughout its life span.
The structure of the composite forms and the interlocking features are meticulously engineered using state-of-the-art CAD software tools and advanced materials science principles. It ensures that the forms interlock seamlessly and securely at all times, creating a high degree of stability for the overall structure. This innovatively designed interlock mechanism not only contributes to the strength and longevity of the apparatus, but also uplifts its aesthetic appeal due to the sleek fitting. The inventive apparatus, as such, boasts of a design that aptly balances between optimum functionality and pleasing aesthetics.
In addition to the above, the given one embodiment under offers an added advantage of easy installation. The well-thought-out interlocking features on the composite forms allow for quick and effortless assembly, saving both time and labor costs. To summarize, the apparatus provides a multifaceted solution that elegantly marries robustness with ease of use, while adhering to high design and efficiency standards.
The composite forms in the one embodiment are crafted with a unique mix of materials that confer an impressive resistance to water, mold, and rot, enhancing their longevity and durability. They are built specifically to withstand all weather extremities, making them not just applicable, but also highly efficient for usage across diverse climatic conditions. The intricate combination of materials not only optimizes their resistance to water but also thwarts the collective and individual growth of mold and rot that typically cause deterioration in similar products.
The one embodiment, hereinafter referred to as the “ABC Forms,” is an automated, multi-faceted protection and reinforcement system created for the preservation and fortification of structures. The ABC Forms can be incorporated into various types of structures that, including but not limited to, buildings, bridges, and homes. The mechanisms and functionalities within the ABC Forms are designed so as to resist and counteract the destructive forces generated by various natural disasters such as earthquakes, storms, extreme weather conditions, fire and other similar events.
The ABC Forms utilize a series of custom-engineered components, made from a proprietary material, that work in conjunction with one another to bestow high levels of resilience on the protected structure. These components are adaptable, their actions respond to and neutralize the effects of the varied natural phenomena they may encounter. Furthermore, ABC Forms are designed to be retrofittable to existing structures and easily capable of integration into new building designs.
Fire resistance is another key feature of ABC Forms. The system includes where desired, intumescent and fire-retardant materials and inventive designs that limit the spread of fire. This basalt component of ABC Forms can withstand high temperatures without losing its structural integrity and it also inhibits the movement of flames within the structure, providing people inside with potentially crucial extra time for escape.
The ABC Forms system is also designed to maintain some degree of functionality even when a section is damaged, contributing to the overall sturdiness of the structure.
This patent describes ABC Forms as an advanced, holistic approach to structural safety. Harnessing proprietary materials and innovative design principles, it offers a ground-breaking solution to structural reinforcement and protection. Apart from its robust performance against natural disasters, the ABC Forms system also provides both environmental and economic benefits by contributing to the long-term sustainability of structures and reducing repair and replacement costs that stem from disaster-related damage.
Diving deeper into the design of the ABC Forms, they exhibit a universal design, permitting users to fit them together effortlessly. This is achieved via the incorporation of compatible interconnections designed into each form. These can be interlocked, ensuring a stable and stiff alignment unlike any other. Furthermore, the locking component of the design eliminates the uncertainty of the structure dismantling or collapsing that is often prevalent with similar traditional assembly options. ABC Forms hence provide a worry-free solution, contributing to peace of mind and offering enhanced efficiency in assembly tasks.
The one embodiment pertains to a digitalized solution to construction and building inspection processes, more specifically, a software-based apparatus that comprises a Digital Twin Diagram (DTD) of a building structure featuring color-coded parts. The DTD uses real-time dynamic data to create a virtual model of the building structure, allowing users to visualize the components of the building structure in a digital space. Each color coding corresponds to a different type of components, such as electrical infrastructure, plumbing, structural components, etc., enabling easy identification and differentiation of different structural parts, thereby facilitating a clearer understanding and better planning for those involved in the construction or maintenance of the building structure.
In addition to the DTD, the one embodiment incorporates a downloadable feature for phones and tablets, ensuring that it is more readily accessible, flexible and portable. This instant accessibility feature extends the utility of the one embodiment as it can be utilized on-the-go, and on multiple devices. This universal accessibility allows for seamless and concurrent multi-platform usage, further improving user convenience and experience.
The apparatus is designed to synergize with augmented reality (AR) display capability, offering an immersive method of interfacing with the DTD. Users can see the color-coded building structure in an AR environment, superimposing the digital twin diagram over the real-world view of the building or the site. This feature provides a comprehensive, three-dimensional comprehension of the building structure and its components, which simplifies and enriches the users' interaction with the building model.
An essential component in the apparatus is the embedded ease-of-use feature that facilitates user interaction with the program. The interface design is focused on intuitiveness and user-friendliness. The color coding, combined with simple touch-screen controls, image zoom features, and easy navigation around the building structure, provide a smooth and intuitive user experience.
The apparatus also incorporates an efficient inspection feature, vital for reducing the time spent examining the condition of the building structure. By using the color-coded DTD, users can quickly identify any irregularities or deviations from the original plan, saving valuable inspection time. This is particularly beneficial during routine inspections or when identifying damages following a natural disaster.
The apparatus also brings significant positive impacts on aspects of mass production, such as assembly and waste reduction. The clear visualization of the building components in the DTD, with the color-coding and AR capabilities, greatly simplifies the assembly process. Users can determine the sequence and method for assembly more accurately, thereby reducing the potential for waste generated due to errors in the assembly process.
Lastly, this one embodiment also directly addresses the significant challenge in the construction industry of managing labor resources. The color-coded DTD's clear and detailed visual display of the construction process can allow for the planning and deployment of human resources more efficiently. By aiding in the prediction and resolution of potential issues that could arise during the construction process, it can prevent unnecessary delays and waste, thereby reducing costs related to labor and materials.
The present one embodiment pertains to a digital twin diagram apparatus that defines a three-dimensional representation of any building structure. This digital twin diagram is revolutionary in the areas of architecture, engineering, and construction, exhibiting enhanced precision and accuracy in computational modeling and simulation of physical structures. The digital twin diagram is not constrained to a specific building type and can be applied for residential, commercial, or industrial buildings. A unique aspect of this technology lies in its ability to capture the real-world details and complexities of building structures, from their geographical specifics to their structural design intricacies.
The digital twin diagram apparatus synthesizes the use of several technologies, including cloud computing, Artificial Intelligence (AI), Internet of Things (IoT), and reality modeling. With these technologies, it replicates the building structure's design, construction, operation, and maintenance on the digital platform. The apparatus includes interfaces to capture real-time data from actual structural components, which is then used to build and update the three-dimensional model. The updated data enhances the apparatus to be more adaptive to the changing circumstances surrounding the physical structure, making it an essential tool for predicting and managing potential issues and improving the overall operational efficiency of the building.
Additionally, the digital twin apparatus contributes to sustainable practices as it allows for identifying potential efficiencies and waste reduction opportunities. For instance, in energy usage, the apparatus could monitor and analyze energy consumption, leading to the development of more energy-efficient solutions. This will not only bring in notable cost savings but also contribute significantly to environmental conservation. In essence, the digital twin diagram is a dynamic, scalable, and resilient technology that promises an optimized, streamlined, and sustainable future in building construction and maintenance.
The present one embodiment relates to an apparatus that provides augmented reality display capability aimed for construction management. The apparatus comprises a processing unit well integrated with numerous components such as a peripheral system, a storage system, a data input system, and an augmented reality display system, among others. The main role of this system is to present a real-time view of a building structure, a feature that is particularly essential for construction professionals involved in planning, designing, executing, and constructing buildings or structures. The most distinguishing feature of this system is the use of color-coded parts that are visualized in their actual place in the building or structure.
The one embodiment employs pre-designed additional features, crafted with an emphasis on easy attachment onto the complex shapes. These additional features are not an afterthought in the design process; rather, they are integrated into the foundation of the design plan itself, thus allowing them to be seamlessly attached during the assembly process. The design of the features can be adapted according to the shape and size of the apparatus, thereby maintaining the integrity of the final product. This addresses the common issue of misalignment or incompatibility in traditional methods.
At the core of the one embodiment is a process that involves predefined docking or attachment points on the complex shaped structures. These spots are a part of the initial design and are specific to the added features. They work as puzzle pieces facilitating their easily attached counterpart for an effortless assembly. The features being pre-designed also eliminate the need for any modification or adjustments during the assembly phase, reducing the likelihood of errors and offering a significant improvement in the assembly productivity. This one embodiment paves the way for a revolutionary approach in assembly processes, with possible applications in various industries ranging from automotive to consumer electronics, where production efficiency and accuracy are of paramount importance.
The presented apparatus includes a construction system that utilizes pre-fabricated components. These components are designed and manufactured ahead of time, taking into consideration various typical architectural technologies, design elements, and construction requirements. This approach allows for rapid on-site assembly, thereby minimizing the time taken for the construction process. This inventive concept is premised on the principle of “Design for Assembly” (DFA), which reduces the overall cost and time required for a construction project through optimization and preplanning of parts and assembly sequences.
The pre-fabricated components used in this apparatus can include a variety of structural elements such as walls, floors, columns, roof trusses, windows, doors, or various other architectural elements. Each component is precisely designed and manufactured in a controlled factory environment, ensuring consistent quality, accuracy, and adherence to specified dimensions and tolerances. This ensures that the components can be seamlessly integrated and assembled on the construction site.
The one embodiment features a system wherein the pre-fabricated components are designed to fit together in a multitude of configurations. This allows for a flexible approach to building design, capable of accommodating a wide variety of architectural styles and structural needs. Unique interlocking mechanisms can be included in the design of components to support easy and secure assembly.
By utilizing pre-fabricated components, the construction system significantly reduces the onsite waste generated during the building process. This not only leads to a more environmental friendly construction approach but also reduces the costs associated with waste disposal. The construction wastes that are typically produced when cutting and fitting materials on the job site are substantially eliminated.
With this one embodiment, the construction process becomes more predictable as it reduces dependence on weather conditions and human factors. Pre-fabricated components are manufactured indoors in a controlled environment, which shields the process from weather disruptions. Furthermore, the precise manufacturing of components also reduces the likelihood of errors or defects.
Another advantage of this construction system is in labor optimization. On-spot construction requiring higher skills and prolonged labor can be transferred to the controlled environment of factories where these components are fabricated. This, in turn, could lead to safer construction environments as fewer workers would be required on-site, and those present would be performing less risky tasks.
In summary, this apparatus introduces a novel construction system that leverages the advantages of pre-fabricated component use. This system transforms the conventional building process by minimizing the time and cost involved, reducing waste, and enhancing the quality of the final structure. As a result of these innovative elements, this system promises to revolutionize the construction process, improving efficiency and providing a more sustainable approach to building construction.
The present one embodiment refers to an apparatus pertaining to the construction industry, more specifically, an innovative mechanism designed to produce a layer of foamed concrete with a defined density range. The focus of the present one embodiment is the foamed concrete layer mentioned, wherein the density is prescribed between 400-1000 kg/m3. This density range has been established following meticulous research and experimentation to guarantee optimum performance in line with the application requirements. Such foamed concrete layer exhibits unique characteristics distinguishing it from conventional foamed concrete and is expected to contribute significantly in redefining the construction industry's standards.
The present one embodiment pertains to a wall structure enhanced for robustness and impact resistance, specifically against projectiles and missiles traveling at high velocities up to 2000 m/s. The one embodiment offers enhanced functional aspects, structural elements, and design characteristics that work together to provide a higher degree of protection, robustness, and stand up to high-kinetic energy impacts unprecedented in prior art. This one embodiment can effectively serve various sectors such as military, industrial, or construction fields that require superior protective barriers and enclosures.
This novel wall structure is characterized by an ingenious blend of construction materials, impact-absorption mechanisms, and design attributes that enable it to resist forces and impacts. The primary component of the wall structure is a proprietary composite material known for its high tensile strength, superior hardness, and impressive shock absorption properties. This material is arranged in layers, with each layer being further enhanced with a network of interconnected reinforcement members fabricated from resilient, high-strength composites. The reinforcement members are strategically arranged and integrated within the composite layers to provide a structural grid that distributes and dissipates the kinetic energy of an incoming projectile or missile, hence diminishing the likelihood of overall failure.
The present one embodiment pertains to an innovative apparatus for pouring concrete that includes a set of pour stops. These pour stops are ingeniously designed to hold the concrete at a desired height level during the pouring process but rather than being welded into place at great time and expense, easily snap into place. The apparatus as such contributes to a more streamlined, efficient and precise method of pouring concrete, wherein the concrete is controlled to form at a desired height for achieving an optimized structural integrity and uniformity.
The pour stops in the apparatus are ergonomically designed, primarily for holding the concrete. They function as vertical impediments or barriers which, when strategically placed, provide a mechanism for maintaining a defined upper limit to the concrete surface during the process of pouring. The height of these pour stops can be adjusted depending upon the requirement of the final structure, providing the apparatus with considerable flexibility and ease of use.
In conclusion, the apparatus for pouring concrete with set of pour stops, as described herein, showcases an innovative advancement in concrete pouring methods. The apparatus contributes to effectiveness, precision, and resourcefulness in the field of construction, capable of improving the quality and consistency of concrete structures. Furthermore, by providing a more refined control over the pouring process, it directly leads to enhanced structural integrity and durability of the constructed structures. By addressing current challenges and deficiencies associated with conventional concrete pouring methods, this one embodiment presents an efficient and sustainable solution that greatly benefits the structural construction industry.
The present one embodiment relates to the field of building construction, more specifically to a floor decking assembly system that is designed for enhanced structural integrity. The system encompasses an apparatus that comprises a floor decking assembly installed upon the beams, which significantly improves the strength and durability of the construction. A unique feature of the design involves snapping the individual components of the floor decking assembly together to ensure a lasting connection and a firmer base for any structure it supports, serving as the foundation for the larger construction.
The central innovation in this patent claim is the method of connecting the floor decking assembly. Instead of traditional methods like nails or screws which could potentially cause splits or cracks in the material, a ‘snapping together’ technique that utilizes pressure and friction to secure the assembly is employed. While this concept might seem simple, its application in floor decking assembly presents a novel enhancement in durability due to the reduction in the use of potentially damaging securing methods. The design allows for the components to join tightly together, to beams, other floor decking segments and pour stops, reducing the potential for water damage, wear, tear, and degradation over time, thereby extending the lifespan of the resulting structure.
The one embodiment further optimizes the process of building construction, offering an effective solution in construction technology. By assembling the floor decking assembly on top of the beams and then connecting them together, without welding, or mechanical fasteners that can take large amounts of labor, the risk of structural instability is minimized, guaranteeing a uniformly strong, durable floor structure that significantly enhances security and safety. This revolutionary ‘snapping together’ technique provides increased resistance to structural failures and ensures a solid foundation for any building structure-from residential homes to commercial properties, thereby creating an innovative shift in construction methodology whilst promoting efficiency and reliability within the industry.
Another aspect to consider is the unique combination of the parts in the floor decking assembly. The components that make up the assembly might be arranged in such a manner that they provide particular advantages once assembled, such as optimized load distribution, enhanced stability, improved safety features, or adapted to specific functional requirements. But this careful arrangement could mean that it takes more time and effort to assemble the floor decking.
The present one embodiment relates to an enhanced structural apparatus that incorporates the use of mesh or rebar within the floor decking assembly, and since it is not subject to corrosion can be closer to the surface, substantially improving the floor or beam load-bearing capacity, rigidity, and durability. More precisely, the one embodiment introduces a novel floor decking assembly system equipped with an integrated network of meshing or rebars and ‘chairs’ or supports, that provide superior structural support, thereby curbing unwarranted flexing, bending, or potential damage subjected by weight or loading pressures. This particular addition offers considerable reinforcement to the floor assembly, significantly increasing its overall strength and resilience while furnishing superior resistance to fracture or breakage. The alternative approach using traditional steel floor decking does not bind with the concrete, is subject to corrosion both from moisture and galvanic corrosion, is expensive and time consuming to install, and is heavier for a given strength.
Employing mesh or rebar within the floor decking assembly fosters increased stability and long-term durability by helping distribute the weight evenly across the decking system. Incremental sections of mesh or rebar are systematically arranged and embedded within the decking material during the construction process. Upon pouring the decking substance, like concrete, over the interconnected mesh or rebar, it hardens around these components, thereby creating a synergistic reinforcement impact. The resulted finished floor decking assembly exhibits enhanced compression tolerance, torsional strength, and overall durability. The flexibility of the mesh or rebar permits nominal flexing under stress without compromising the structural stability or leading to catastrophic failure of the floor decking assembly.
The present one embodiment pertains to an innovative design improvement of a decking assembly, specifically incorporating pour stops installed at the edges of the floor decking assembly. The pour stops are designed as an improved safety and functionality feature. Installed similar to existing pour stops, to the edges of the deck, but with integral assembly features, they provide a boundary wall for wet concrete during construction and hand pouring, preventing the concrete from spilling over. The deck assembly, conjoined with these particularized pour stops, delivers a higher degree of control and accuracy over conventional decking systems. The primary objective of these pour stops is to enhance the efficiency and safety during the construction process, allowing for a smooth flat floor, reducing potential wastage and systematizing the spreading procedure of wet materials.
To facilitate installation, these pour stops are designed with a convenient attachment mechanism that can be easily executed onto the edges of the floor decking assembly and integrating them mechanically, with the beam molds. Installation takes minimal time and does not require specialized tools, making the process user-friendly. The level of ease this provides significantly reduces time and labor cost during development. In conclusion, this claimed one embodiment presents a breakthrough in the decking assembly design, integrating pour stops at the decking edges so that the loads due to gravity engage the features retaining the system being approximately 90 degrees to each other. The one embodiment has far-reaching benefits in terms of operational efficiency, waste reduction, cost, and time savings, as well as enhanced safety in construction workflows.
The present one embodiment relates to a novel and improved apparatus that includes a locking mechanism designed to secure pour stops in place with adjacent beams, columns, and floor decking during the pouring process.
Various modifications and alterations of the invention will become apparent to those skilled in the art without departing from the spirit and scope of the invention, which is defined by the accompanying claims. It should be noted that steps recited in any method claims below do not necessarily need to be performed in the order that they are recited. Those of ordinary skill in the art will recognize variations in performing the steps from the order in which they are recited. In addition, the lack of mention or discussion of a feature, step, or component provides the basis for claims where the absent feature or component is excluded by way of a proviso or similar claim language.
While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not of limitation. The various diagrams may depict an example architectural or other configuration for the invention, which is done to aid in understanding the features and functionality that may be included in the invention. The invention is not restricted to the illustrated example architectures or configurations, but the desired features may be implemented using a variety of alternative architectures and configurations. Indeed, it will be apparent to one of skill in the art how alternative functional, logical or physical partitioning and configurations may be implemented to implement the desired features of the present invention. Also, a multitude of different constituent module names other than those depicted herein may be applied to the various partitions. Additionally, with regard to flow diagrams, operational descriptions and method claims, the order in which the steps are presented herein shall not mandate that various embodiments be implemented to perform the recited functionality in the same order unless the context dictates otherwise.
Although the invention is described above in terms of various exemplary embodiments and implementations, it should be understood that the various features, aspects and functionality described in one or more of the individual embodiments are not limited in their applicability to the particular embodiment with which they are described, but instead may be applied, alone or in various combinations, to one or more of the other embodiments of the invention, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments.
Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as meaning “including, without limitation” or the such as; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; the terms “a” or “an” should be read as meaning “at least one,” “one or more” or the such as; and adjectives such as “conventional,” “traditional,” “normal,” “standard,” “known” and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Hence, where this document refers to technologies that would be apparent or known to one of ordinary skill in the art, such technologies encompass those apparent or known to the skilled artisan now or at any time in the future.
A group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and/or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should also be read as “and/or” unless expressly stated otherwise. Furthermore, although items, elements or components of the invention may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated.
The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other such as phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent. The use of the term “module” does not imply that the components or functionality described or claimed as part of the module are all configured in a common package. Indeed, any or all of the various components of a module, whether control logic or other components, may be combined in a single package or separately maintained and may further be distributed across multiple locations.
Additionally, the various embodiments set forth herein are described in terms of exemplary block diagrams, flow charts and other illustrations. As will become apparent to one of ordinary skills in the art after reading this document, the illustrated embodiments and their various alternatives may be implemented without confinement to the illustrated examples. For example, block diagrams and their accompanying description should not be construed as mandating a particular architecture or configuration.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A composite building form, comprising:

a first layer of basalt fibers;

a layer of dicyclopentadiene (DCPD) foam or inert material disposed between the first layer of basalt fibers and a second layer of basalt fibers; and

a reactive surface on the first and or second outer layer of basalt fibers that bonds to concrete.

2. The composite building form of claim 1, wherein the first and second layers of basalt fibers are mechanically separated to provide thermal and acoustic insulation wherein the layer of DCPD foam or inert material is disposed between the first and second layers of basalt fibers.

3. The composite building form of claim 1, wherein the reactive surface on the fibers is a pozzolan coating.

4. The composite building form of claim 1, wherein the composite material further comprises a layer of glass fibers or carbon fibers.

5. The composite building form of claim 1, wherein the composite building form is shaped to form a column, a pillar, floor decking, a beam, pour stop, stairs, window frame, door frame or mesh or other regular geometry.

6. The composite building form of claim 1, wherein the composite building form is prefabricated, lightweight, and easy to assemble.

7. The composite building form of claim 1, wherein at least one form, comprises a composite material including basalt, glass, carbon, or other fibers, and a reactive surface that bonds to concrete.

8. A method of constructing a building, comprising:

assembling a plurality of composite building forms according to claim 1;

pouring concrete into the composite building forms; and

allowing the concrete to cure.

9. The method of claim 8, wherein the forms interlock without custom tools and remain in place after pouring concrete, reinforcing a structure and protecting the structure, and wherein the forms are assembled using color-coded parts, diagrams, or digital twins.

10. The method of claim 8, wherein the composite building forms are interlocked without the need for custom tools.

11. The method of claim 8, wherein the composite building forms are color-coded.

12. The method of claim 8, further comprising cutting the composite building forms to size and feature using a waterjet or router.

13. The method of claim 8, further expanding the features by forming a composite building structure with concrete poured into the composite building with molded interlocking features that remain in place during and after the curing process.

14. The method of claim 8, wherein at least one composite building form comprises a composite material including basalt, glass, carbon, or other fibers, and a reactive surface that bonds to concrete.

15. The method of claim 8, wherein the composite building forms interlock without custom tools, wherein the forms remain in place after pouring concrete, reinforcing the structure and protecting the structure.

16. The method of claim 8 where the composite building forms and spacers can be interlocking and allow precise spacing and integration of cables, pipes, conduits and other features allowing rapid assembly of piping systems, electrical systems and other features.

17. The method of claim 8, wherein the composite building forms are assembled using color-coded parts, diagrams, or digital twins.

18. The apparatus of claim 1, comprising a composite material prefabricated to a specific building design and shipped to a building location for assembly.

19. The apparatus of claim 1, wherein the composite material is made of a combination of two or more materials, including but not limited to metals, polymers, and ceramics.

20. The apparatus of claim 1, comprising a mesh, form, composite structure or geogrid made of basalt or glass fiber sized to snap into place, with a pozzolan coating to enhance a pull-out resistance in concrete or geopolymer binder.