Manufacturing method for a building system in regards to structural and environmental factors

Abstract

A method for designing and manufacturing a building system in regards to environmental factors including, acquiring a visual image for determining topographic characteristics of a surface, generating a set of architectural geometries in a computing system, creating design models representing an architectural design of the building system, geometric comparison and evaluation of the topographic characteristics with the architectural geometries, selecting a design model for manufacturing the building system, manufacturing a plurality of interlockable building bricks, obtaining a plurality of interlockable modular structure by combining the interlockable building bricks, each of said bricks having a shell portion formed on the inner core of the interlockable building bricks so that the modular structure has common outer surface formed from said shell portion of each brick. The shell portion includes TiO.sub.2 exhibiting a radiation-protective effect and manufacture of the building system in regards to environmental factors.

Claims

1. A method of manufacturing a building system with regards to environmental factors, comprising the steps of: acquiring a visual image for determination of topographic characteristics of a surface in a dune field: generating a set of architectural geometries with respect to the topographic characteristics of the surface in a computing system; creating a plurality of design models representing an architectural design of the building system to be manufactured based on a selected architectural geometry in the computing system; geometrically comparing and evaluating the topographic characteristics with the set of the architectural geometries formed by a plurality of interlockable building bricks, in the computing system; selecting one of the design models for manufacturing the building system; manufacturing the plurality of interlockable building bricks, wherein each of the interlockable building bricks comprises an inner core with walls having one or more protrusions shaped and sized to engage one or more corresponding recesses of a neighboring interlockable building brick; obtaining a plurality of interlockable modular structure by combining the plurality of the interlockable building bricks, wherein each of the interlockable building bricks has a shell portion formed on the inner core of the interlockable building bricks so that each of the interlockable modular structure has a common outer surface formed from the shell portion of each of the interlockable building bricks, wherein the shell portion comprises TiO.sub.2; and manufacturing the building system according to the selected design model with the interlockable modular structure.

2. The method according to claim 1, wherein the interlockable building bricks are configured to match with corresponding protrusions and recesses of neighboring interlockable building bricks to allow multiple form sections to be connected to create a larger form.

3. The method according to claim 1, wherein parameters of dimensions of the design models and material specialties are varied when defining the set of the architectural geometries for geometrically comparing and evaluating the topographic characteristics.

4. The method according to claim 1, wherein the set of the architectural geometries comprises a series of non-uniform rational bi-spline (NURBS) surfaces.

5. The method according to claim 1, further comprising a step of generating a plurality of primitive curves used to create the set of the architectural geometries.

6. The method according to claim 5, wherein the plurality of the primitive curves and dimensions of the primitive curves are varied when generating the set of the architectural geometries.

7. The method of according to claim 1, wherein the building system is shaped as a fully enclosed dome configuration with respect to the selected design model.

8. The method according to claim 1, wherein each of the interlockable building bricks further comprises voids as a through hole extending in a longitudinal axis of each of the interlockable building brick.

9. The method according to claim 1, wherein the building system is made of an in-situ material.

10. The method according to claim 9, wherein the in-situ material is regolith.

11. The method according to claim 10, wherein the regolith comprises 30-45% w/w of SiO.sub.2, 18-26% w/w of Al.sub.2O.sub.3, 2-10% w/w of TiO.sub.2, 9-20% w/w of Fe.sub.2O.sub.3 or FeO, and 3-10% w/w of CaO.

12. The method according to claim 10, wherein the regolith is sintered.

13. The method according to claim 10, wherein the regolith is melted.

14. The method according to claim 1, wherein the TiO.sub.2 used in the shell portion is obtained by extracting from local soil.

15. The method according to claim 1, wherein the TiO.sub.2 used in the shell portion is obtained by extracting from regolith.

16. The method according to claim 1, wherein the plurality of the interlockable building bricks are manufactured by a 3D Printer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The figures whose brief explanations are herewith provided are solely intended for providing a better understanding of the present invention and are as such not intended to define the scope of protection or the context in which said scope is to be interpreted in the absence of the description.

(2) Referring now to the drawings in which like reference numbers represent corresponding parts throughout:

(3) FIG. 1 shows an exploded top view of a modular structure (100) according to the present invention.

(4) FIG. 2 shows a top view of a modular structure (100) according to the present invention.

(5) FIG. 3 shows an example of a plurality of modular structure combined together according to the present invention.

(6) FIG. 4a and FIG. 4b show perspective views of the modular structure (100) according to the present invention.

(7) FIG. 5 shows a perspective and front views of an interlockable building brick (40) according to present invention.

(8) FIG. 6 shows a perspective view of a building structure (90) in accordance with the design model according to the present invention.

(9) FIG. 7a to FIG. 16a show schematic views of examples of architectural geometries (1a) according to the present invention.

(10) FIG. 7b to FIG. 16b show a top view of examples of primitive curves (1a) according to the present invention.

(11) FIG. 17 show a top view of geometric modeling provided by dune field simulation.

DETAILED DESCRIPTION

(12) The list of reference numerals used in the appended drawings are as follows; 1a Architectural geometry 1b Primitive curve 11 Protrusion 12 Recess 13 Void 20 Inner core 30, 40, 50 Brick 71 Design model according to Werner model 72 Design model according to Von Neumann model 80 Shell portion 90 Building system 100 Modular structure

(13) Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings which are given solely for the purpose of exemplifying embodiments according to the present invention.

(14) According to the present invention, a method of a building system (90) with regards to environmental factors is proposed in which an interlockable building brick (30, 40, 50) for constituting a modular structure (100) having a shell structure (80) containing TiO.sub.2 exhibiting a radiation-protective effect are manufacture especially with using in-situ materials. Within the scope of this invention, a modular structure (100) is processed to respond to the dynamic formation on the topography by increasing resistance of the structure against the severe environmental condition. The building system (90) can be a construction which is manufactured with respect to a design model created in a computing system after various tests and analyzes for obtaining optimum design against environmental factors for example in an extraterrestrial fields.

(15) According to the present invention, the method of a building system (90) with regards to environmental factors mainly comprising the steps of; acquisition of a visual image for determination of topographic characteristics of a surface in a dune field; using a design model (71, 72) obtained as a result of dune field simulation to reduce the wind load on the surface of Mars on the structure; generation of a set of architectural geometries (1a) with respect to the topographic characteristic of the surface in a computing system; creating a plurality of design models representing an architectural design of the building system (90) according to a selected architectural geometry (1a) in the computing system; geometric comparison and evaluation of the topographic characteristics with the architectural geometries (1a) constituted by a plurality of interlockable building bricks (100) of a plurality of interlockable building bricks (30,40,50) in the computing system; selection a design model for manufacturing the building system (90); manufacture of a plurality of interlockable building bricks (30,40,50), said each interlockable building brick (30,40,50) comprising an inner core (20) with walls having one or more protrusions (11) shaped and sized to engage one or more corresponding recesses (12) of a neighbouring brick (30,40,50); obtaining a plurality of modular structures (100) by combining the plurality of interlockable building bricks (30,40,50), each of said bricks (30,40,50) having a shell portion (80) formed on the inner core (20) of the interlockable building bricks (30,40,50) so that the modular structure (100) has common outer surface formed from said shell portion (80) of each brick (30,40,50), wherein said shell portion (80) comprises TiO.sub.2; and manufactures of the building system (90) according to the selected design model by using said interlockable modular structures (100).

(16) In an example of the invention, there is provided an efficient system in which in situ materials such as Martian regolith is converted into interlocking structural elements as modular design solutions that can create various design possibilities. In response to the severe environmental conditions and heavy wind storms on Mars, sand dunes form on the Martian topography. Sand dune formations represent fluidity and complexity with a high level of articulation and coherence from a systematic perspective, which is investigated initially in the design process. Wind flow above the surface of Mars creates land forms representative of self-organized patterns. Mathematical models are used to understand natural phenomena. Complex, nonlinear, dynamic systems are used to simulate landscape phenomena in geomorphology. Through computer simulations related to the transport of sand by wind, different forms may be produced, including Barchan, crescentic ridge, linear, and star natural dune classes. The basic mathematical model for the dune field was developed by Werner (DOI: 10.1130/0091-7613(1995)023<1107:EDCSAA>2.3.CO;2). The main principle of the algorithm is that the sand batches are transported in a stochastic procedure through which erosion, transport, and deposition processes are determined by chance (DOI: 10.1016/S0169-555X(02)00187-3). Abstract models are able to describe the dune field evolution As an embodiment, for determination of topographic characteristics of a surface of a dune field in Mars, first a satellite view as a visual image reflecting the local characteristic of Martian topography is analyzed. Through computer simulations related to the transport of sand by wind, different forms may be produced, including Barchan, crescentic ridge, linear, and star natural dune classes. A dune field simulator software can be exploited to understand the dynamic characteristic of the geomorphology of Martian land caused by the extreme wind conditions.

(17) The parameters in Table 1 can be referred during simulation. Various other models can be implemented into the system by using existing model structures. Each model can be run with several methods for finding steep slopes, such as the Moore, deterministic Von Neumann, or stochastic. After setting the dune field dimensions and a sand height, an initialization method is specified as random or uniform. By running the simulation, the dune field elevation is displayed. Two dune field simulations can be conducted for comparison. The length and width of the area can be defined as 256×256, and the sand height value can be 2. The algorithm was based on the Werner model with the selection of “no erosion in shadow.” The neighborhood method was specified as Von Neumann deterministic. The two simulations only differ in their hop value, L, which was assigned as 1 and 3, respectively. By running the simulations for the same periods of time, the results can be compared. By altering configuration of the self-organized pattern changed along with the maximum height that the system can reach. With an L of 1, the height of the dunes reached up to 14; with an L of 3, it reached a maximum of 24. On the basis of the top view and elevation, the geometry is modelled three-dimensionally in the geometric modeling software as shown in FIG. 17. The obtained models are suitable for the local characteristic of Martian topography and severe environmental conditions and heavy wind storms on Mars.

(18) TABLE-US-00001 TABLE 1 Parameters of dune field simulator Model B. Werner (1995) + no erosion in shadow Neighbourhood Von Neumann, deterministic Initial conditions Random Length × Width 256 × 256 Sand Height 2 p(sand) 0.6 p(No Sand) 0.4 L(hop) 3 Show Elevation

(19) A set of architectural geometries (1a) with respect to the topographic characteristic can be generated comprising of a series of nonuniform rational bispline surfaces (NURBS) which is a standard form of surface description in computing system (Piegl and Tiller ISBN 978-3-642-97385-7). On the basis of the dune field simulation results, the overall height of the dune field is taken into consideration in the arrangement of a geometric cluster; thus, the cluster offers a variety of surfaces of highly rational geometries, such as domes, and free-form geometries with greater differentiation and complexity. When defining the architectural geometry for geometric comparison of the topographic characteristics, the parameters such as dimensions, material properties are taken into consideration and can be varied.

(20) In some exemplary embodiments of the invention, a set of architectural geometries (1a) can be developed within a software (such as software called as a “Rhino 5 3 D geometric modeling”) including surface operation tools such as sweep 1& 2, loft, revolve and network surface. As seen in the examples of FIG. 7 to FIG. 16, the architectural geometry (1a) may be configured in a wide variety of shapes. Wherein the primitive curves (1b) and dimensions of said bricks (30, 40, 50) can be varied when generating architectural geometries.

(21) For example, in the embodiment of FIG. 7a, the length, width and height values are entered as dimensions 10, 10 and 5, respectively, in said software, and the sweep 1 operator is used by assigning a primitive curve in FIG. 7b, as an initial curve.

(22) In another embodiment of FIG. 8a, the length, width and height values are entered as dimensions 10, 10 and 5, respectively, in said software, and the loft operator is used by assigning a primitive curve in FIG. 8a, as an initial curve.

(23) In another embodiment of FIG. 9a, the diameter and height values are entered as dimensions 10 and 5, respectively, in said software, and the sweep1 operator is used by assigning a primitive curve in FIG. 9a, as an initial curve.

(24) In the embodiment of FIG. 10a, the length, width and height values are entered as dimensions 13.64, 12.27 and 4.11, respectively, in said software, and the sweep2 operator is used by assigning a primitive curve in FIG. 10b, as an initial curve.

(25) In the embodiment of FIG. 11a, the length-I, length-II, height-I and height-II values are entered as dimensions 12.23, 9.73, 5.02 and 4.36, respectively, in said software, and the sweep2 operator is used by assigning a primitive curve in FIG. 11b, as an initial curve.

(26) In the embodiment of FIG. 12a, width, the arc length, and height values are entered as dimensions 17.36, 28.54 and 8.30, respectively, in said software, and the revolve operator is used by assigning a primitive curve in FIG. 12b, as an initial curve.

(27) In the embodiment of FIG. 13a, the width, arc length, and height values are entered as dimensions 19.44, 28.08 and 6.04, respectively, in said software, and a network surface operator is used by assigning a primitive curve in FIG. 13b, as an initial curve.

(28) In the embodiment of FIG. 14a, the length, width, height-I and height-II values are entered as dimensions 20.69, 10.22, 4.96 and 6.96, respectively, in said software, and a network surface operator is used by assigning a primitive curve in FIG. 14b, as an initial curve.

(29) In the embodiment of FIG. 15a, the length, width and height values are entered as dimensions 44.49, 8.55 and 9.07 respectively, in said software, and a network surface operator is used by assigning a primitive curve in FIG. 15b, as an initial curve.

(30) In the embodiment of FIG. 16a, the length, width and height values are entered as dimensions 4.90, 3.07 and 2.98 respectively, in said software, and a network surface operator is used by assigning a primitive curve in FIG. 10b as an initial curve.

(31) Following the generation of the architectural geometry (1a) through the surface operation, the design model is created representing an architectural design (1a) of the building system (90) according to a selected architectural geometry (1a) in the computing system by the means of the creation of the interlockable modules of the structure.

(32) In an example, a software called Rhino can be used for the creation of the interlockable building bricks (30,40,50) of the modular structure (100). Said bricks (30,40,50) are configured to match with corresponding protrusions and recesses of another brick (30,40,50) to allow multiple form sections to be connected to create a larger form. As shown in FIG. 3, a toothed flat module is designed to be interconnected with larger surfaces, which are multiples of triangular forms, including squares.

(33) In another embodiment, as shown in FIG. 4; each interlockable building brick (30, 40, 50) comprises an inner core (20) with walls having one or more protrusions (11) shaped and sized to engage one or more corresponding recesses (12) of a neighbouring brick (30,40,50); each of said bricks having an outer shell portion (80) formed on the inner core (20) of the interlockable building bricks (30,40,50) so that modular structure (100) has common outer surface formed from said outer shell portion (80) of each brick, wherein said outer shell portion (80) comprises TiO.sub.2. These interlockable building bricks (30,40,50) (can be abbreviated as T-brick) containing TiO.sub.2 used in outer shell portion (80) can also be obtained by extracting from local soil.

(34) In another embodiment as shown in FIG. 5, schematically illustrates typical interlockable building bricks (30,40,50) can include a plurality of voids (13) as a through hole extending longitudinal axis of the brick, thereby reducing volume and weight.

(35) In an embodiment, the manufacture of interlockable building bricks (30, 40, 50) may be carried out by a 3D Printer to form a building system (90) in accordance with the design model. Said building system (90) can be shaped as a fully enclosed dome configuration, as shown in FIG. 6.

(36) In an embodiment of the present invention, the building system (90) can be made of in-situ material. In an example of this embodiment, the in-situ material may be regolith which can be processed by sintering or melting.

(37) In another example of this embodiment, Martian regolith may be in situ material which used to create interlockable building bricks (30, 40, 50). The ingredients in the Johnson Space Center (JSC) Mars-1 Martian Simulant can be used as a reference for the design of the material system, for which the typical regolith is characterized in Table 1, as specified in the challenge document (Nine Sigma 2015)

(38) TABLE-US-00002 TABLE 2 Regolith Composition on Marian Land (Mass %) (Data from Nine Sigma 2015) Oxide JSC Mars-1 Martian Simulant SiO.sub.2 43.7 TiO.sub.2 3.8 Al.sub.2O.sub.3 23.4 Fe.sub.2O.sub.3/FeO 15.3 MnO 0.3 MgO 3.4 CaO 6.2 Na.sub.2O 2.4 K.sub.2O 0.6 P.sub.2O.sub.5 0.9 Total 100.0

(39) In another example of this embodiment, wherein said the regolith composition can include the following (w/w):

(40) TABLE-US-00003 SiO.sub.2 30-45%  Al.sub.20.sub.3 18-26%  TiO.sub.2 2-10% Fe.sub.2O.sub.3/FeO 9-20% CaO 3-10%

(41) In another embodiment of the present invention, the interlockable building brick (30, 40, 50) is suitable for payload package constraints shown in Table 2 which is described by NASA is provided. The maximum payload is indicated as 700 kg for a volume of 2×1×1 m. For every kilogram of native materials used, 11 kg of transportation propellant and spacecraft mass is saved (Nine Sigma 2015). The reference material for T-brick has the density of 2,410 kg/m.sup.3. The size of the modular structure (100) is restricted to meet the payload package constraints, and one side of a module cannot be larger than 2 m, as determined by the U and V values of the initial geometry. As shown FIG. 2, the modular structure (100) having the dimensions of the initial module which are 98×117 cm is obtained within the scope of this embodiment.

(42) TABLE-US-00004 TABLE 3 Payload Package Constraints (Data from Nine Sigma 2015) Parameter Value Maximum payload mass [mp.sub.max (kg)] 700 Payload dimension [length (m)] 2 Payload dimension [height (m)] 1 Payload dimension [width (m)] 1 Maximum payload volume [V.sub.max (m.sup.3)] 2

(43) As an example, Finite Element Method (FEM) can be applied for geometric comparison and evaluation of the topographic characteristics with the architectural geometries (1a) constituted by a modular structure (100) of a plurality of interlockable building bricks (30,40,50) in the computing system. Considering the existing topography on Mars, FEM by the Rhino scan-and-solve feature can be undertaken for static structural performance simulation to assess the displacements and stresses on the design model shown in FIG. 6. A scalar force of 1,500 kN can be applied and according to the simulation results, the minimum and maximum displacements range between 3.55709×10.sup.−10 and 7.58634×10.sup.−5 m as shown in Table 3.

(44) TABLE-US-00005 TABLE 4 Results of the FEM Simulation: Displacements and Stresses on the Geometry Result extrema Minimum Maximum x-displacement (m) −2.90731 × 10.sup.−5 1.83117 × 10.sup.−5 y-displacement (m) −2.98874 × 10.sup.−5 3.56451 × 10.sup.−5 z-displacement (m) −7.17405 × 10.sup.−5  3.265 × 10.sup.−7 Total displacement (m)  3.55709 × 10.sup.−10 7.58634 × 10.sup.−5 von Mises stress (Pa) 1,797.24 789,926 Max principal stress (Pa) −208,469 315,395 Mean principal stress (Pa) −244,371 78,033.8 Min principal stress (Pa) −1.01573 × 10.sup.6  51,035.7

(45) The present invention is not limited to the examples shown and described. The configuration described herein and the particulars thereof can be readily applied to a variety of products and applications. It is therefore understood that the above-described embodiments are illustrative of only a few of the possible specific embodiments which can represent applications of the invention. Numerous and varied other arrangements can be made by those skilled in the art without departing from the spirit and scope of the invention.