FIELD

The present disclosure relates to free-form structures.

DEFINITION As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicate otherwise.

Free-form structure - A free-form structure is an irregularly shaped building with curved surfaces. BACKGROUND

The background information herein below relates to the present disclosure but is not necessarily prior art.

Free-form structures involve intricately shaped designs are often challenging to construct by conventional method of construction. Successful completion of the free-form structures depends on two critical factors viz. compliance of the method of construction to the technical specifications, and the timeframe needed in following the method of construction of the free form structure. Complex shaped designs of free-form structures are difficult to be accomplished by conventional method of construction. Moreover, conventional methods of construction often involves following a specific procedure, which is time consuming as well as it significantly raises the incurred expenses. Lastly, inclement weather conditions such as extreme temperatures, humidity, fluctuating wind loads, seismic loads, self weight of snow loads, and any other designed input loads pose great difficulty in constructing a free-from structure by a conventional method of construction. Often, a compromise is needed on one of the essential factors discussed above. There is, therefore, felt a need for a method of making a free-form structure to overcome the above said problems. OBJECTS

Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:

An object of the present disclosure is to provide a method of making a free-form structure; Another object of the present disclosure is to provide a method of making a free-form structure that is complex in configuration

Still another object of the present disclosure is to provide a method of making a free-form structure that complies with the structural specifications laid out; and

Yet another object of the present disclosure is to provide a method of making a free-form structure that eliminates longer construction times; and

Still another object of the present disclosure is to provide a method of making a free-form structure that employs a compound material which decreases cost of construction.

Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure. SUMMARY

The present disclosure discloses a method of making a free-form structure comprising the steps of:

• erecting an endoskeleton by interconnecting load bearing members of the structure together in a three dimensional grid pattern on a substrate; · preparing an exoskeleton by placing scaffolds and shutterings on the endoskeleton, the scaffolds configured to allow access to construction materials and workmen, and the shutters arranged for allowing introduction of construction material between the exoskeleton and the endoskeleton, as well as the endoskeleton; pouring of semi-solid materials into the skins followed by curing of the semi-solid materials to form a body of the free-form structure; • appyling at least one skin layer over the body of the free -from structure to achieve a desired surface finish.

In an embodiment, recycled plastics and elastomers are filled inside the body to achieve desired mechanical properties.

In an embodiment, reinforcements are attached to the body to augment structural strength of the free-form structure;

In an embodiment, the endoskeleton is configured to be detachable to the free-form structure.

In an embodiment, the scaffolds and shutters are configured to be detachable to the free-form structure.

In a preferred embodiment, a plurality of voids is configured to be maintained inside the free form structure to facilitate weight reduction of the free-form structure.

In another embodiment, the plurality of voids is configured in the form of pressurized air containers. The plurality of voids have variable dimensions.

In another embodiment, the reinforcements are of irregularly shaped profiles.

In another embodiment, the skin is made of a metallic material or a polymeric material.

DETAILED DESCRIPTION

Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.

Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.

The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The ter s “comprises”, “comprising”, “including” and “having” are open-ended transitional phrases and therefore specify the presence of stated features, elements but do not forbid the presence or addition of one or more other features, elements. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.

When an element is referred to as being “mounted on”, “engaged to”, “connected to” or “coupled to” another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed elements.

Terms such as “inner”, “outer”, “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.

The present disclosure envisages a method of making a free-form structure in accordance with an embodiment of the present disclosure. The method of making a free-form structure includes forming an endoskeleton, an exoskeleton, and a body. The method of making a free form structure further involves strategic insertion of fillers and reinforcements. Finally, the method involves applying skin layers on top of the body which form the extrinsic part of the free-form structure.

The endoskeleton which forms the intrinsic part of the free-form structure, is initially erected to support the free-form structure either partially or entirely. In an embodiment, the endoskeleton is a permanent integral part of the free-form structure. In another embodiment, the endoskeleton is a detachable part of the free-form structure. The endoskeleton includes numerous load bearing members, and the method of its construction involves interconnecting the load bearing members with each other with the help of various types of joints such as fasteners, welded elements and the likes in a three-dimensional grid pattern on a substrate. The method of making the endoskeleton governs the structural strength of the free-form structure, as it not only strengthens the endoskeleton but also imparts the necessary mobility to the endoskeleton through linkages or joints. Structural members like plates, sections, threads, membranes, perforations, pneumatic containers, tubes, rods, coires and clusters are provided in the endoskeleton, as they facilitate the desired customization of functional requirements of the endoskeleton. In an embodiment, the endoskeleton is a monolithic structure. In another embodiment, the endoskeleton includes multiple joints that connect the load bearing members, as desired. In an embodiment, the endoskeleton is prestressed. In another embodiment, the endoskeleton is post tensioned to impart more rigidity and strength. Such load bearing members are usually finitely dimensioned structural elements that form a grid pattern. The grid pattern of the structural members facilitate uniform division of incident loads on the free-form structure, which results in avoiding stress concentration in a particular location, thereby preventing failure of the free-form structure. In another embodiment, the endoskeleton is designed to be collapsible by suitable means of collapsing, in case of which the collapsing action can be realized either by manual means or by automated means. The endoskeleton is designed in a way so as to support the gross weight of the free-form structure, thus either completely or partially eliminating reliance on any additional supports required to be designed separately. The geometry of the members typically consists of regular shapes as well as irregular shapes as desired. In an embodiment, the free-form structure assumes a shell shape. The sizes of the members are designed so that the free-form structure thus formed has either constant or varying shell thickness. Additionally, a plurality of endoskeletons including a plurality of free-form structures with a plurality of shells are blended with each other to form multi-layered free-form structure. It should be noted that each of the endoskeletons possess the ability to support themselves independently or in combination with other free form structures. In yet another embodiment, the endoskeleton is either suspended by a single support or multiple supports. Further, composite engineered materials are often preferred, as the required strength can be imparted to the intricate shapes. Further, voids provided inside the free-form structure provide structural integrity and also facilitate reduction in overall weight. Thus, the overall time required in constructing the endoskeleton is cut down significantly, as grid structure enables ease of construction at the same time ensures maintaining the required stiffness of the free-form structure.

The method of making the free-form structure further includes forming an exoskeleton which forms the extrinsic part of the free-form structure. In an embodiment of the present disclosure, a plurality of scaffolds and/or a plurality of shutterings are surrounded on the endoskeleton. Scaffolds are temporary structural elements that are supported on the endoskeleton that facilitate movement of workmen and material required in construction of the free-form structure. Shuttering on the other hand are temporarily formed support skins to allow introduction of construction material between the exoskeleton and the endoskeleton, as well as within the endoskeleton. This facilitates enhanced rigidity while the semi-solid material is being introduced. In an embodiment, both the plurality of scaffolds and the plurality of shutterings are dismantled from the free-form structure and removed. In an alternate embodiment of the present disclosure, the shutters and scaffolds are left as is in the free-form structure without dismantling and subsequent removal thereof, which further augments the structural integrity.

The method of making the free-form structure further includes forming the body that engulfs the endoskeleton. The body of the structure is formed by pouring semi-solid materials having excellent flow ability, which is followed by curing of the semi-solid materials under controlled conditions to ensure structural integrity and to achieve the desired level of artisanship. The semi-solid materials are typically composites containing viscous or semi viscous or fluid materials that offer strong adhesion as well as binding material such as concrete which offers excellent bond strength. To achieve the required structural strength, the binding material and the viscous fluids are typically mixed in a desired proportion 4:1. In an embodiment, the semi-solid materials poured in forming the body of the endoskeleton occupies the entire volume. In an embodiment, the semi-solid materials poured in forming the body of the endoskeleton occupies partial volume. In yet another embodiment, this proportion is variable to achieve the desired physical properties. To further augment the structural strength, the design of the free-form structure includes voids that are provided inside the body, which further aid in weight reduction of the free-form structure. In an embodiment, voids are designed by adding into the binding material, while in another embodiment voids are designed as air containers made of suitable material. The air containers are designed to be either rigid or flexible. In another embodiment, the air containers are either designed to be pressurized with means for pressurizing or non-pressurized. The voids designed having varying sizes and shapes are strategically placed at locations in the free-form structure, which helps in reducing the overall weight of the free-form structure while maintaining the desired structural strength on the body formed. Thus, void design significantly reduces the weight of the free-form structure, by almost one tenth as compared to a free-form structure with no voids. Furthermore, the deisgn of the air containers provide a storage space for fluids needed in the process of curing, as needed either during construction or during the service life of the free-form structure, thereby eliminating the need of additional design considerations to be taken into account. The method of making the free-form structure further includes inserting fillers in between the body that facilitate varying of the mechanical properties of the free-form structure. Such fillers are typically elastomers and plastics obtained by recycling materials. Thus, the free form structure of the present disclosure offers an economically viable construction. Additionally, the use of fillers facilitates improved sustainability of the structure.

The method of making the free-form structure still further includes attaching reinforcements in the form of rods, wires, clips and cables that increase strength of the free-form structure, especially against all external dynamic loads, when structures made of conventional building materials such as concrete are unable to provide the necessary strength. This arises from the fact that conventional materials such as concrete are stronger in compression than in tension. Moreover, the reinforcements are available in standard sizes which facilitates ease of construction. In an alternate embodiment, the reinforcements are custom made having irregular shapes and sizes to cater to the specific needs of the desired structure.

The method of making the free-form structure further comprises applying a skin to provide the desired surface finish. The skin layer includes materials from the group consisting of a cloth, paint, varnish, cable reinforced membranes, cable girders, tiles, metals, powdered materials made of composites. The skin layer not only provides desired surface finish but also guards against inclement weather conditions especially extreme temperature and humidity that spoil the aesthetic appearance. In an alternate embodiment, there are a plurality of skin layers applied on the body of the free-form structure.

The method of the present disclosure facilitates construction of intricately shaped structures as well as being compliant to the specifications laid out as desired. Aditionally, the method offers a systematic approach to construction which results in speed of construction. Moreever, use of recyclable materials if facilitated which further decreases the overall cost of a project.

The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure. TECHNICAL ADVANCEMENTS

The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a method of making a free-form structure that:

• allows flexibility in constructing complex shapes while adhering to the designed structural specifications;

• enhances speed of construction; and

• utilizes recyclable materials that can be compounded with traditionally available materials, thereby offering a cost-effective solution.

The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.

ECONOMICAL SIGNIFICANCE

One of the objects of the Patent Law is to provide protection to new technologies in all fields and domain of technologies. The new technologies shall or may contribute in the country economy growth by way of involvement of new efficient and quality method or product manufacturing in India.

To provide the protection of new technologies by patenting the product or process will contribute significant for innovation development in the country. Further by granting patent the patentee can contribute in manufacturing the new product or new process of manufacturing by himself or by technology collaboration or through the licensing.

The applicant submits that the present disclosure will contribute in country economy, which is one of the purposes to enact the Patents Act, 1970. The product in accordance with present invention will be in great demand in country and worldwide due to novel technical features of the present invention is a technical advancement in the field of free-form structures. The technology in accordance with present disclosure will provide product cheaper, saving in time of total process of manufacturing. The saving in production time will improve the productivity, and cost cutting of the product, which will directly contribute to economy of the country. The product will contribute new concept in free-form structures, wherein patented process/product will be used. The present disclosure will replace the whole concept of the method of making a free-form structure will facilitate in less build time and requirement of less materials of construction. The product is developed in the national interest and will contribute to country economy.

The economy significance details requirement may be called during the examination. Only after filing of this Patent application, the applicant can work publicly related to present disclosure product/process/method. The applicant will disclose all the details related to the economic significance contribution after the protection of invention. The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

Any discussion of documents, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application. The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary. While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.