WO2020172654A1 - Self-constructing structures - Google Patents

Abstract

Disclosed are devices, systems, and methods for self-constructing structures. In particular, a mold for forming a structure includes an inflatable inner balloon, a non-inflatable outer shell coupled to the inner balloon about a base circumference, the outer shell having an apex and an opening disposed at the apex, and a pump in fluid communication with the opening of the outer shell; wherein, when the inner balloon is inflated, a gap is formed between the inner balloon and the outer shell for containing a building material, and the outer shell comprises a dome shape.

Description

SELF-CONSTRUCTING STRUCTURES

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Application No. 62/809,686 filed February 24, 2019, which is hereby incorporated by reference in its entirety.

BACKGROUND

[0002] Embodiments of the present disclosure generally relate to self-constructing structures. In particular, the present disclosure describes dome-shaped structures fabricated of materials available near the construction site.

BRIEF SUMMARY

[0003] The present disclosure is generally directed to portable reusable devices for creating low-cost sustainable self-constructing architectural building structures of varying sizes, configurations, functions, and types of materials using inflatable molds and requiring the labor of only one person to construct through synergy of structural design, building material, and automation of on-site construction process with a small variety of machines that require low skill level to operate.

[0004] In various embodiments, a mold for forming a structure includes an inflatable inner balloon, a non-inflatable outer shell coupled to the inner balloon about a base circumference, the outer shell having an apex and an opening disposed at the apex, and a pump in fluid communication with the opening of the outer shell; wherein, when the inner balloon is inflated, a gap is formed between the inner balloon and the outer shell for containing a building material, and the outer shell comprises a dome shape. [0005] In various embodiments, a building material is disposed between the inner shell and the outer shell. In various embodiments, the building material includes water, mud, concrete, clay, a water-sediment mixture, and/or a water-sand mixture. In various embodiments, the building material includes an additive selected from lime and a biologically-based material. In various embodiments, the building material may include biologically-based material includes seeds, vines, grass, plants, moss, and/or fungus. In various embodiments, the outer shell includes a flexible material. In various embodiments, the outer shell includes a rigid material. In various embodiments, the outer shell is removable. In various embodiments, the outer shell includes a zipper. In various embodiments, the outer shell includes a plurality of partitions. In various embodiments, the mold includes a tube extending from the opening of the outer shell that is in fluid communication with the pump. In various embodiments, the pump is one of a plurality of pumps. In various embodiments, a vibration mechanism may be disposed on the exterior surface of the mold. In various embodiments, the mold may include a source of sonic energy that is applied to the mold. In various embodiments, the mold includes a heater.

[0006] In various embodiments, the mold includes one or more laser sensors configured to measure a size and a shape of the inner balloon by adjusting a flow of air from one or more air pumps in fluid communication with the inner balloon. In various embodiments, the mold includes a pressure gauge configured to measure air pressure within the inner balloon. In various embodiments, the mold includes a net having a dome shape and disposed around the inner balloon. In various embodiments, the net is secured to ground via anchors selected from the group consisting of: corkscrew anchors and stakes. In various embodiments, the outer shell includes a net having a dome shape. In various embodiments, the net is secured to ground via anchors selected from the group consisting of: corkscrew anchors and stakes. In various embodiments, the mold further includes a liner conforming to the gap between the inner balloon and outer shell. The liner has an apex and an opening at the apex that is aligned with the opening of the outer shell. In various embodiments, the liner is made of a flexible material. In various embodiments, the liner is made of a water-impervious material. In various embodiments, the liner is reusable. In various embodiments, the liner is disposable.

[0007] In various embodiments, a method for forming a structure includes providing a mold including an inflatable inner balloon and a non-inflatable outer shell coupled to the inner balloon about a base circumference, the outer shell having an apex and an opening disposed at the apex. The inner balloon is inflated to form a gap between the inner balloon and the outer shell. Building material is added into the opening of the outer shell thereby filling the gap with the building material. The outer shell is removed. The inner balloon is deflated. The inner balloon is removed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Fig. 1 illustrates a cross-section of a self-constructing structure having a dome shape according to an embodiment of the present disclosure.

[0009] Fig. 2 illustrates a cross-section of a self-constructing structure having a dome shape according to an embodiment of the present disclosure.

[0010] Figs. 3A-3B illustrate various cross-sections of a self-constructing structure having a dome shape according to an embodiment of the present disclosure.

[0011] Fig. 4 illustrates a cross-sectional exploded view of a self-constructing structure having a dome shape according to an embodiment of the present disclosure.

[0012] Fig. 5 illustrates a flow diagram of a method for manufacturing a self-constructing structure having a dome shape according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0013] As used herein in the specification,“a” or“an” may mean one or more. As used herein in the claim(s), when used in conjunction with the word“comprising”, the words“a” or“an” may mean one or more than one. For example, reference to“an antibody” is a reference to from one to many antibodies. As used herein“another” may mean at least a second or more.

[0014] The term“ amendment’ or“ amending’’ as used herein refers to material added to or combined with primary building material in order to alter its characteristics or constitution for an intended purpose. For example, adding lime to a clay material to increase its hardness when the material dries or adding plant seed to a soil material used for construction in order to establish plant roots or vines through the soil material to increase structural strength of the combined material or improve its aesthetic appearance.

[0015] The term“ amendment” as used herein refers to additives to the water or building material to change the properties of the material, such as the addition of fly ash to increase the material strength of concrete.

[0016] The term“ anchor” as used herein refers to an instrument or method of holding a thing in place.

[0017] The term“ balloon” as used herein refers to a material inflated with air and which has its structural shape and rigidity maintained by the pressure of the air inflating it. As used herein, the balloon is hemispherical in shape and its purpose is to provide structural support from below and provide shape to the building material during construction. The balloon may be the inner shell of the mold. The balloon may be secured in place and reinforced to achieve higher air pressures and greater rigidity by a dome-shaped net conforming the exterior of the balloon and anchored to the ground around the balloon’s base circumference. In the uninflated or collapsed configuration, the balloon can include a pattern of folds (e.g, helical) that facilitate a controlled and predictable expansion/inflation upon pressurization. In some embodiments, select regions of the balloon can be expanded/inflated in a sequential manner.

[0018] The term“c/ay” as used herein refers to material of generally consistent, fine grain size. Clay is either commercially available or available in naturally occurring regolith.

[0019] The term “ concrete” as used herein refers to commercially available particles typically combined with water for emplacement and used as a building material considered finished after setting and drying. Concrete is generally comprised of particles of material of differing grain sizes.

[0020] The term“dome” as used herein refers to a structure with a circular base and hemispherical or hemispherical-like roof or ceiling. The dome need not be a continuous structure, but rather can include discontinuities, e.g. gaps or openings, within to provide various structural features, e.g. windows or slots.

[0021] The term“liner” as used herein refers to a single continuous hollow container, a bag, comprised of polyethylene, vinyl, or other flexible material that is water impervious. The liner lines the gap between the balloon and outer shell and conforms to the shape of the gap formed by the balloon, outer shell, and ground between the balloon and outer shell. The liner is the component of the mold that, when used, the construction material comes into direct contact with during construction and within which the construction material is contained and held in place while being deposited. When filled with water or construction material, the liner is reinforced from below by the inflated balloon and from above by the pressure of the water or construction material in the liner pressing outward and meeting resistance against the outer shell. The liner has an apex and an opening disposed at the apex aligned with the opening in the outer shell and into which water and construction material are deposited into the liner during construction. When the liner is positioned between the inflated hemispherical balloon and the dome-shaped shell, and when the liner is filled with water or construction material, the liner is dome-shaped in the shape of the final building structure. The liner may be reusable or disposable.

[0022] The term“ modify” or“modification” as used herein in the context of a structure refers to alterations of a dome structure’s original shape, including removal of pieces from the structure to make openings for windows or walls, adding material to structures, such as to create corridors linking structures together, or inserting objects into the mold or altering the mold such that openings or additions become a part of the resulting dome structure when it is created without the need for removing or adding material to the dome structure after it has been created.

[0023] The term“mold” as used herein refers to a hollow cavity, which, in the case of the disclosure, forms a desired shape when filled with water or building material. In various embodiments, the mold includes the complete system, including the shell, balloon, nets, pumps, and ground anchors.

[0024] The term“pump” as used herein refers to either an object used for moving or pressurizing air or water, or the action of moving or pressurizing air or water.

[0025] The term“ regolith” as used herein refers to a layer of heterogeneous and loose deposits overlaying solid rock. Regolith includes soil, rock fragments, dust and other related materials and is present on Earth and other planets, moons and celestial objects.

[0026] The term“self-constructing” as used herein refers to the building of a structure with total labor equal to less than that of two people working full time in an ordinary business day: fewer than 80 hours of work per week. The term“ shelF or“outer shelF refers to the outermost component of the mold that holds construction material in place during construction. The shell is comprised of a continuous, reusable dome-shaped material secured in place over the balloon and anchored to the ground around the shell’s base circumference, the shell having an apex and an opening disposed at the apex into which water or building material enters, thereby filling the gap between the balloon and the shell. The shell may be water-impervious or not water-impervious, or water-impervious when used in combination with a water-impervious liner. The shell may be flexible or not flexible. The shell may consist of a dome-shaped net.

[0027] The term“ sort” as used herein refers to the accumulation of sediment according to uniformity of grain size.

[0028] The term“ structure” or“building as used herein, unless otherwise stated, refers to a human-made, free-standing, immobile architectural object with an interior space for occupancy, shelter, or storage.

[0029] The term“ treating’’ or“ treatment’ as used herein refers to applying a process or material to a building material to alter its characteristics for an intended purpose. For example, adding water to clay in order to shape the clay into bricks and bond the clay particles when dried, or heating wet clay to accelerate drying of the clay or baking the clay to increase the clay’s strength. Treating can also include coating a building material to increase its resistance to weathering or to improve its aesthetic appearance, such as applying a coating of paint.

[0030] The fundamental designs, materials, and construction processes of many modern building structures have generally not changed over the past century. Modem buildings continue to be constructed using unsustainable materials that are often mined or harvested from a geographically distant location and then transported to a construction site from that distant location. Modern buildings also require unnecessarily large amounts of human labor and energy, lack resilience, are overly specific in function, and are costly to construct, maintain, demolish, and dispose.

[0031] Construction of these buildings continues to require large amounts of labor applied toward redundant building designs and construction processes that can be made more efficient by automation. The inefficiencies of modern construction may be partially solved by pre-fabricated structures which increase efficiency of construction by automating redundant processes in the creation of building components. However, pre-fabricated structures often require excessive resources for transporting the prefabricated components, which may be very large, to construction locations or storing the prefabricated components for extended periods of time.

[0032] The designs of modern architectural structures may generally involve flat planar surfaces joined at angles. A simple example includes four flat walls joined at 90° angles with a flat roof joined to the top of the walls. Such structures, in addition to unnecessarily introducing structural weaknesses at the joints, are subject to accelerated deterioration from winds, rain, and destruction by storms and natural disasters. The structures also pose storm water control challenges requiring additional systems and parts ( e.g ., guttering, etc.). The separation of building components into structural components (e.g., frames, beams, etc.) comprised of pieces that are connected together with bonding and fastening mechanisms (e.g, nails, bolts, braces, etc.) and finishing components (e.g, dry wall, moldings, siding, roofing shingles and tiles, etc.) wastes space, introduces points of structural weakness, and diminishes longevity of most modem buildings. In many instances, this separation invites intrusion by pests, for example, rodents, insects, water, and mold infiltration in gaps between building materials.

[0033] Modem buildings may be constructed of a wide range of materials (e.g, glues, plastics, synthetic fibers, metals, woods, preservatives, paints and other coatings) that often originate far from the site of building construction and result in high construction, maintenance, repair, demolition, and disposal costs. Many of the building materials introduce toxins into the human living environment (e.g, volatile organic compounds [VOCs] from glues), making buildings less safe and more susceptible to fires and off-gassing of dangerous toxins during fires. Furthermore, many building structures are designed to be overly specific in their function ( e.g ., specific designs for residences, office/administrative buildings, or storage/warehousing buildings) and the high cost of construction of the building structures requires them to be made permanent. Although the buildings fulfill a basic purpose to provide shelter, the over-specificity of design and cost of construction results in inflexibility of structure use, use of space, and use of real estate.

[0034] Accordingly, there exists a need for novel devices and methods for creating low-cost, sustainable, scalable structures for a wide range of applications including housing, recreation, landscaping, office spaces, storage, and manufacturing using materials that are in close proximity to the construction site.

[0035] The present disclosure is generally directed to methods and portable reusable devices for creating low-cost sustainable self-constructing dome-shaped architectural building structures of varying sizes, configurations, functions, and types of materials using inflatable molds and requiring the labor of only one person to construct through synergy of structural design, building material, and automation of on-site construction process with a small variety of machines that require low skill level to operate. The present disclosure provides for a means for creating these structures with minimal waste. The present disclosure provides for a means by which commercially available building material or naturally available local sediment or regolith onsite is utilized for building material of buildings by mimicking natural geological processes to suspend sediment in water and direct sediment transport, deposition, settling, compaction, and hardening through the control and direction of water flow, air pressure and movement, and thermal and vibratory kinetic energy with pumps, vibrators, fans, and heaters in conjunction with inflatable dome-shaped molds to select, move, arrange, emplace, shape, settle, dry and harden building material into dome-shaped building structures with minimal cost, labor, and energy. The disclosure consists of establishing a dome structure mold by inflating a balloon in the shape of the dome and acting as the inner shell of the mold, with a flexible exterior shell comprised of flexible material and attached to the balloon at the base at ground level. The outer shell has a circular opening at the top into which building material is added until the mold fills with the building material. When ready, the exterior shell is removed and the balloon is deflated and removed, leaving the dome building structure comprised of the building material. Amending, treating, or modifying the building material during or after its emplacement with the molds, methods, and devices described herein, such as with additives to accelerate building material drying, accelerating building material deposition with vibrational kinetic energy, hardening the material with heat, and coating the building material with paint are included in the scope of the disclosure.

[0036] Under some embodiments the building material is water that freezes into ice. Under some embodiments, the building material is comprised of regolith naturally present at the construction site or suspended in a nearby flowing water body ( e.g ., river or creek). Under some embodiments using sediment or regolith as building material, the mold is filled with sediment-laden water from a river or soil naturally present at the construction site and added through the opening in the mold by tubes and water pumps. The water overflows the mold through the opening, and runs down the exterior of the outer shell onto the ground, where the water suspends sediments located on the ground around the mold and the sediment-laden water is re-circulated back into the mold with water pumps and tubes to continue transporting sediment into the mold. Sediment is carried toward the mold with water pumps spraying ground across the area around the mold toward the mold and fans placed on the ground in the area around the mold blows material toward the mold. As sediment-laden water enters the mold, the velocity of water flow decreases with descent of the flowing water into the mold, the sediments settle into and are deposited in the mold as the velocity decreases, and the mold eventually fills with sediment deposited in the mold. Material that floats exits the mold through the water overflowing through the mold opening, and sediment size and density is controlled by controlling the flow rate of water entering the mold. Use of heaters, vibrators, and sound speakers warms the water and adds kinetic vibrational energy that accelerates sedimentation, compaction, and drying and increases material strength of the finished structure. Building material can be amended or treated during or after its emplacement in the mold, such as with additives during deposition of building material in the mold ( e.g ., drying accelerators or hardeners) or coatings (e.g., paint) or heat treatment (e.g., sintering) after completion of deposition into the mold to control a wide range of factors including construction speed, structure strength and resilience, and aesthetics, depending on intended function of the building structure.

[0037] The building material for all past and present building structures results from natural geological processes. Clay that is used for bricks, adobe, and other building material is ordinarily collected from sedimentary deposits of particles of small grain size. The sedimentary material is naturally formed by the weathering of rocks from water, wind, and biological activity. Finer grain-size material, due to its light weight, becomes suspended in and transported by moving water; higher velocity water carries heavier particles. As the flow velocity decreases, the particles settle from the water and form deposits. The clay material used for construction is ordinarily collected from deposits found at river beds, lakes, or other water bodies where the sediments from upland origins have accumulated as a result of these geological processes and transported to a plant for shaping and heating the material into square or rectangular shaped bricks of redundant sizes and shapes. The bricks are then transported to construction sites and used for building construction, typically by stacking and cementing the bricks into place.

[0038] This multi-step process of building material extraction and utilization is time- consuming and unnecessarily labor and energy-intensive, as many construction locations naturally have present within the regolith of the construction site more than enough natural material of grain sizes suitable for construction. The natural processes that sort regolith grain sizes into clay deposits useful for construction are mimicked by the present disclosure by applying flowing water to suspend and move sediments of small grain size directly to the construction project from the regolith already present at the construction site. This eliminates the need for preparing and/or transporting building material to the construction site. Also, under the present disclosure the building material is not pressed into bricks of redundant square or rectangular shapes and sizes, and instead the building material is directly inserted into a mold of a full building structure with automated processes ( e.g ., a water pump and tubes) thereby eliminating the need for additional labor-intensive, energy-intensive, and time- consuming construction steps such as storing and staging building material and machinery and stacking and cementing bricks into place. Furthermore, the homogenous building material has strength characteristics and resilience to weathering not present in non- homogenous building materials such as bricks bonded together with concrete. Additionally, embodiments of the present disclosure utilize building material naturally present within the existing regolith of a construction site, thereby eliminating the need to import building materials from distant locations for construction, repair, maintenance, addition, and replacement of the building structure. Finally, utilization of materials naturally present within the regolith of a construction site minimizes resources required for demolition and disposal of material: collapsing a structure comprised of the construction site’s natural regolith and allowing the structure to weather and erode returns the construction site back to its natural or near-natural condition without the need for disposal of demolition materials at a landfill. The present disclosure of creating dome-shaped building structures comprised of local regolith harnesses all of these advantages of utilizing local regolith for building material. [0039] Lifting building materials to higher elevation and joining them into place for common modern building structures is energy and labor inefficient and generally requires the use of many different tools, pieces of machinery, careful sequencing of separate construction processes, specialized skill sets and training, and many hours of labor. Frames are usually assembled and erected first, followed by lifting and attaching various types of filling and finishing materials and objects requiring many unnecessary movements of materials, machinery, tools, and objects into proper positions for carrying, staging, fitting, fastening, and setting/drying construction components. The present disclosure eliminates these inefficiencies by greatly reducing sequences and processes of construction by consolidating them into uniform basic stages; automating and mechanizing the lifting and emplacement of building material with the use of pumps; and utilizing the mechanisms of sorting, transporting, and depositing of material that occur by natural geological processes. Furthermore, the present disclosure utilizes vibratory kinetic energy to accelerate the settling, setting, compacting, hardening, and drying of building material similar to the use of concrete vibrators.

[0040] With their curvatures approximating those of inherently stable spherical structures found at all scales across nature, from microscopic ( e.g ., water bubbles) to cosmic (e.g, stars and planets), domes are among the most inherently stable of all possible scalable building structure shapes. The present disclosure utilizes many of the advantages of the dome shape during the construction process and in the resulting structures it produces. Consistency, simplicity, strength, low drag and inherent resilience against damage and weathering from rain and wind, scalability, and aesthetically pleasing visible appearance of a dome’s curving shape are utilized by the construction molds, methods, and devices of the disclosure described herein. The present disclosure utilizes the geometric symmetry and even distribution and balancing of forces across the wall of a dome structure to enable the use of relatively thin and flexible, inflatable material of the balloon and thin and flexible material of the outer shell of the mold to support large amounts of evenly distributed weight from water and building material with the use of air pressure for structural rigidity of the mold during construction. The geometric symmetry of the dome shape of the mold also helps to ensure that the building material will deposit evenly within the mold as it is applied into the opening at the top of the mold and settles toward the bottom. Additionally, because the total area of a cross-section of a dome mold in the present disclosure increases vertically, flow velocity of sediment-laden water declines within the mold from top of the dome structure to bottom, and this decline of flow velocity of the water with decrease in elevation within the mold accelerates the deposition of building material in the mold by the process of sedimentation. Furthermore, during construction, the geometric symmetry of the dome shape helps to ensure that water overflowing from the top of the of mold is generally distributed evenly from the opening in the mold down across the outside of the outer dome shell during construction so that the water is available around the mold’s perimeter to be re-circulated for suspending and moving sediment back into the dome.

[0041] The dome shape lends itself well to the establishment of visibly consistent appearance when constructing numerous dome structures of similar or varying sizes and configurations in visible proximity to each other; the present disclosure utilizes this visually appealing result. Arrangements of multiple structures resulting from the disclosure can include creating smaller dome structures within larger dome structures or joining together dome structures of similar or varying sizes or creating numerous dome structures in visual proximity to each other. Dome structures resulting from the disclosure can be modified to remove material from the structures for purposes of creating windows and doors. Dome structures resulting from the disclosure can be treated with heat and coatings, such as paint or glaze, applied to the internal or external surface of the dome structure. Dome structures resulting from the disclosure can be anchored with straps and reinforced to withstand natural disasters, such as tornadoes, hurricanes, floods, storm surges, tsunamis, or fires. The disclosure can be used to create extraterrestrial dome structures or underwater dome structures.

[0042] In some embodiments, the structures resulting from application of the molds, methods, and devices are of sizes, configurations, and materials resulting in impermanent structures as toys for childhood play. In these embodiments, the resulting structures are of relatively small size, ranging in volumetric size from those of a toy sandcastle with a base diameter of approximately 2 feet to a base diameter of approximately 6 feet. In these embodiments the structures are of relatively limited height, from approximately 1 linear foot to up to approximately 3 linear feet, and the resulting dome structures are made from impermanent materials and arrangements of materials, such as ice, dried sand, and dried mud.

[0043] In some embodiments, the structures resulting from application of the molds, methods, and devices are of sizes, configurations, and materials having temporary recreational, ornamental, lawn, pet shelter, chicken coop, or other temporary, seasonal or impermanent emergency shelter functions. In some embodiments, the structures resulting from application of the molds, methods, and devices are domes. In some embodiments, the resulting dome structures are of sizes ranging from those of doghouses to garden trestles and multi-person camping tents, with base diameters ranging in size from approximately 4 feet to approximately 20 feet, with configurations having heights ranging from 2 feet to 20 or more feet. In some embodiments, materials for the structures are either comprised of natural regolith material ( e.g ., from the naturally present soil on the ground at the construction site), sediment from an adjacent sediment-laden water body, such as a river, or water frozen into ice in cold climates or during winter seasons. In some embodiments the mold is filled with water that freezes and the ice is the building material. In some embodiments, regolith or sediment from a nearby sediment-laden water body such as a river is the building material and the pumping action of elevating the water into the opening of the mold with water pumps serves to sort sediment entering the mold into fine, consistently-sized sediments that are suited for the building material of the structures and method of construction. In some embodiments, local regolith is used as the building material and application of water into a moat created around the mold suspends sediments from soil in the ground that are pumped into the mold with water pumps. In some embodiments a heater is used to accelerate sedimentation in the mold and accelerate drying of the building material. In some embodiments, modulating water flow rate into the mold opening, selects for finer sediments (slower water flow rate, and slower construction rate), larger sediments (faster water flow rate, and faster construction rate), or optimized combinations of larger and smaller sediments depending on the structure’s intended function, needs of the user, and time available for structure creation. In some embodiments, application of sonic energy from sound speakers prevents sediments from sticking to the mold during sedimentation, accelerates sedimentation, and improves compaction of sediments and density, rigidity, and strength of resulting structures. In some embodiments, a heater is used to heat air temperatures within the dome building structures to over 600F to sinter and harden the building material. In some embodiments, amendments to the sediments such as lime or biologically-based materials (e.g., seeds of annual flowering plants or perennial vines) improves structural strength, insulation, water and weather resistance, and aesthetic appearance as appropriate for intended purposes.

[0044] In some embodiments, the structures resulting from application of the molds, methods, and devices are of sizes, configurations, and materials resulting in permanent applications, such as long-term residential housing; warehouses, sheds, hangars, or garages; office buildings or art studios; or manufacturing facilities. In these embodiments, the resulting structures are of sizes ranging from storage sheds to residential houses, with base diameters ranging in size from approximately 10 feet to over 100 feet, with configurations having heights ranging from approximately 5 feet to over 100 feet. In some embodiments, the materials for the structures are either comprised of commercially available building material such as concrete or are comprised of material taken from natural regolith from the soil at the construction site or the building material is comprised of sediment from a nearby sediment-laden water body such as a river. In some embodiments, local regolith is used as the building material and application of water into a moat created around the mold and/or a small temporary pond near the mold suspends sediments from soil in the ground that are pumped into the mold with water pumps. In some embodiments, the pond may be circular. In some embodiments a heater is used to accelerate sedimentation in the mold and accelerate drying of the building material. In some embodiments, modulating water flow rate into the mold opening selects for finer sediments (slower water flow rate, and slower construction rate), larger sediments (faster water flow rate, and faster construction rate), or optimized combinations of larger and smaller sediments depending on the structure’s intended function, needs of the user, and time available for structure creation. In some embodiments, application of sonic energy from sound speakers prevents sediments from sticking to the mold during sedimentation, accelerates sedimentation, and improves compaction of sediments and density, rigidity, and strength of resulting structures. In some embodiments, amendments to the sediments such as lime or biologically-based materials ( e.g seeds of annual flowering plants or perennial vines) improves structural strength, insulation, water and weather resistance, and aesthetic appearance as appropriate for intended purposes.

[0045] In some embodiments, a method of forming a structure of ice, comprising a) establishing a mold of a building structure shaped like a dome comprised of an inner shell that is an inflated balloon attached at its base to a flexible outer shell that is water-impervious and has an opening in the outer shell’s top; b) adding water through the opening in the outer shell, such that the mold around the outside of the balloon fills with water; and c) deflating the balloon and removing the mold after the water has frozen, thereby having created a dome structure of frozen water, is provided herein.

[0046] In some embodiments, a method for creating temporary dome building structures of sand or dried mud, comprising a) establishing a mold of a structure shaped like a dome comprised of an inner shell that is an inflated balloon attached at its base to a flexible outer shell that is soil-impervious and has an opening in the outer shell’s top; b) adding wet sand or mud through the opening in the outer shell, such that the mold around the outside of the balloon fills with wet sand or mud; c) removing the outer shell of the mold and deflating and removing the balloon after the sand or mud has sufficiently dried, thereby having created a dome structure of dried sand or mud, is provided herein; and d) optionally applying amendments to the sand or mud that can consist of lime for additional hardening or seeds or seedlings of vines, grass, creeping plants, or other plants, moss, or fungus for biologically strengthening the structure or improving the aesthetics of the structure with growth of the organisms.

[0047] In some embodiments, a method of forming a structure from commercially available clay or concrete, comprising a) establishing a mold of a structure shaped like a dome comprised of an inner shell that is an inflated balloon attached at its base to a flexible outer shell that is water-impervious and has an opening in the outer shell’s top; b) pumping clay or concrete mixed with water into the mold; c) optionally maintaining consistency of the dome shape and size while being filled with clay or concrete with use of laser sensors monitoring distances within the balloon so that air pressure from an air pump is applied to control air pressure in the balloon; d) optionally applying sound waves from one or more speakers at constant or varying frequencies from within the balloon to prevent clay or concrete from sticking to the balloon, accelerate settling of clay or concrete in the mold, accelerate drying of clay or concrete in the mold, and increase density and compaction of clay or concrete within the mold; e) optionally applying heat from a heater within the balloon to accelerate drying of the clay or concrete; and f) removing the outer shell of the mold and deflating and removing the balloon, thereby having created a dome structure of clay or concrete, is provided herein.

[0048] In some embodiments, a method of forming a structure from sediment-laden water, comprising a) establishing a mold of a structure shaped like a dome comprised of an inner shell that is an inflated balloon attached at its base to a flexible outer shell that is water- impervious and has an opening in the outer shell’s top; b) applying water to the naturally present regolith on the ground around the mold to suspend sediments from the regolith in the water or drawing water from a sediment-laden water body such as a sediment-laden river; c) continuously pumping the water containing the suspended sediments, from water established around the mold or from a nearby water body, into the mold such that the mold around the outside of the balloon fills with water and then the mold fills with sediment as sediment settles in the mold while excess water pours from the mold’s opening back on the ground around the dome where it is re-circulated back into the mold carrying sediment or the water returns to the nearby water body; d) optionally controlling the flow rate of water pumped into the mold to control the size and rate of sediment entering the mold; e) optionally applying moving air in a circular motion, tending toward the center where the mold is placed, with fans on the ground around the outside of the mold to move jetsam directly into the mold or toward the water entering it; f) optionally applying heat from a heater within the balloon to accelerate sedimentation in the mold; g) optionally applying sound waves from one or more speakers at constant or varying frequencies and/or intensities from within the balloon to prevent sediment from sticking to the balloon and to accelerate settling of sediment in the mold, accelerate rate of dewatering/drying of sediment in the mold, and increase density and compaction of settled sediment within the mold; h) optionally maintaining consistency of the dome shape and size when filled with sediment by using laser measuring devices monitoring distances within the balloon so that air pressure from an air pump to control air pressure in the balloon; i) removing the outer shell of the mold from the top of the dome to the bottom; j) deflating the balloon and removing the mold, thereby having created a dome building structure, is provided herein; k) optionally applying heat to the inner surface of the sediment to accelerate and control rate of drying and hardening of the sediment, including gradually raising the air temperature within the dome structure to above 600F to sinter the sediment; and 1) optionally applying amendments to the sediment material that is added to the mold that can consist of lime for additional hardening or seeds or seedlings of vines, grass, creeping plants, or other plants, moss, or fungus for biologically strengthening the structure or improving the aesthetics of the structure with growth of the organisms.

[0049] In one aspect, a device, comprising a) an inflatable balloon that inflates to a dome shape comprising the inside shell of a mold for a dome structure and with a valve for holding air pressure, connecting an air pump, and deflating the balloon; b) a water-impervious material loosely fitting over the outside surface of a) and connected to a) at its base at ground level comprising the outside layer of the dome structure mold with an opening at the top into which water is added and with water-sealed zippers extending vertically for opening and closing the mold; and c) a detachable air pump for inflating a).

[0050] In another aspect, a device, comprising a) an inflatable balloon that inflates to a dome shape comprising the inside shell of a mold for a dome structure and with a valve for holding air pressure in the balloon, connecting an air pump, and deflating the balloon; b) a sediment- impervious material loosely fitting to the outside surface of a) and connected to a) at its base at ground level comprising the outside layer of the dome structure mold with an opening at the top into which sand or mud is added and with zippers extending vertically for opening and closing the mold; and c) a detachable air pump for inflating a).

[0051] In another aspect, a device, comprising a) an inflatable balloon that inflates to a dome shape comprising the inside layer of a shell for a dome structure and with one or more valves for holding air pressure in the balloon, connecting to an air pump, and deflating the balloon; b) a water-impervious material loosely fitting to the outside surface of a) and connected to a) at its base at ground level comprising the outside shell of a dome structure mold with an opening at the top into which sediment-laden water is added and with water-sealed zippers extending vertically with weighted strings for closing and opening the outer shell of the dome structure mold; c) one or more detachable air pumps for inflating a); d) one or more tubes along the outside of b) extending from approximately ground surface or further to the opening in b) and connected to water pumps for pumping sediment-laden water into the mold formed by a) and b); e) a water hose spraying the ground or filling and moving in a circular motion water in a dug out moat to create the sediment-laden water supplied into d).

[0052] In yet another aspect, a device, comprising a) an inflatable balloon that inflates to a dome shape comprising the inside layer of a shell for a dome structure and with one or more valves for holding air pressure in the balloon, connecting to an air pump, and deflating the balloon; b) a water-impervious material loosely fitting to the outside surface of a) and connected to a) at its base at ground level comprising the outside shell of a dome structure mold with an opening at the top into which sediment-laden water is added and with water- sealed zippers extending vertically with weighted strings for closing and opening the outer shell of the dome structure mold; c) one or more detachable air pumps for inflating a); d) one or more tubes along the outside of b) extending from approximately ground surface or further to the opening in b) and connected to water pumps for pumping sediment-laden water into the mold formed by a) and b); e) a water hose spraying the ground or filling and moving in a circular motion water in a dug out moat to create the sediment-laden water supplied into d); f) one or more fans emplaced along ground service directed to supply jetsam directly into the mold or the water that enters the mold; g) up to one or more laser linear distance measurement sensors placed at the center inside of the balloon at ground level to monitor the distance from the sensor to at least one point along the inside of the inflated balloon; h) up to one or more detachable air pumps to modulate air pressure within the balloon to maintain consistency of the mold’s structure based on information provided by g); i) up to one or more sound speakers placed on the ground at the center inside a) to produce sound waves at a constant frequency and/or intensity or varying frequencies and/or intensities against the interior walls of a); j) up to one or more vibrators located along the interior of a) or exterior of b) to provide vibrations to the mold at a constant frequency and/or intensity or varying frequencies and/or intensities; k) one or more heater units centrally located at ground level within a); and 1) one or more heater units to raise and maintain air temperature within dome building structure to above 600F to sinter building material.

[0053] Exemplary Uses and Methods of the Present Disclosure

[0054] In one aspect, a method for creating dome structures of ice, comprising a) inflating a mold of a structure shaped like a dome comprised of an inner shell that is air and water impervious, a balloon, and an outer shell that is water-impervious with an opening at the top; b) adding water, either from melted ice or snow located onsite or another source, through the opening and into the area between the balloon and outer lining, such that the mold fills with water; and c) removing the outer shell and deflating and removing the balloon after the water has frozen, thereby having created an ice dome structure of frozen water, is provided herein.

[0055] Numerous embodiments are further provided that can be applied to any aspect of the present disclosure described herein. For example, in some embodiments, the material of the resulting structure is commercially available concrete or clay. In some embodiments, the material of the resulting structure is sand or soil. In some embodiments, the material of the resulting structure is clay from the construction site’s naturally present regolith.

[0056] In another aspect, a method of creating temporary dome structures of sand or dried mud, comprising a) inflating the balloon of a dome-shaped mold comprised of an inner lining that is the balloon and an outer lining of fabric that is impervious to sand or soil with an opening at the top; b) adding wet sand or mud through the opening and into the area between the balloon and outer lining, such that the mold fills with wet sand or mud; c) removing the outer lining of the mold and deflating and removing the balloon after the sand or mud has sufficiently dried, thereby having created a dome structure of sand or dried mud, is provided herein; and d) optionally applying amendments to the sand or mud that is added to the mold that can consist of lime for additional hardening or seeds or seedlings of vines, grass, creeping plants, or other plants, moss, or fungus for biologically strengthening the structure or improving the aesthetics of the structure with growth of the organisms.

[0057] In another aspect, a method of creating permanent solid dome structures, comprising a) inflating the balloon of a dome-shaped mold of a structure with an inner lining that is the balloon and an outer lining that is sediment-impervious with an opening at the top; b) continuously pumping water containing suspended sediments into the opening in the outer shell at the top of the mold such that the sediment-laden water enters the space between the balloon and outer shell and such that the sediments settle within the space and water overflows from the opening at the top of the mold until the mold fills with sediment; c) optionally controlling the flow rate of water pumped into the mold to control the size, shape, and density of sediment entering the mold and rate of water and sediment entering the mold; d) optionally applying and controlling vibrational kinetic energy to the water in the mold by rapidly expanding and contracting air pressure in the balloon of the mold with an air pump at constant or varying frequencies or applying sound waves with a speaker at consistent or varying frequencies from within the balloon of the mold to control the size and density of sediment settling within the mold, rate of settling of sediment in the mold, rate of dewatering/drying of sediment in the mold, and density and compaction of settled sediment within the mold; e) optionally maintaining consistency of the dome shape and size while being filled with sediment with use of laser measuring devices monitoring distances within the balloon so that air pressure from an air pump can be applied as needed to control air pressure in the balloon for the purpose of maintaining consistency of the mold’s size and shape through day/night temperature changes that can affect air pressure within the balloon and ambient atmospheric air pressure changes that can occur outside the balloon; f) removing the outer shell of the mold from the top of the dome to the bottom as (or after) the sediment dries; g) optionally applying electrical current or heat to the outer surface of the sediment as it dries to control rate of drying and hardening of the sediment; h) and deflating the balloon and removing the mold, thereby having created a dome structure, is provided herein; i) optionally applying electrical current or heat to the inner surface of the sediment as the balloon deflates to control rate of drying and hardening of the sediment from the top of the dome to the bottom of the dome; and j) optionally applying amendments to the sediment material that is added to the mold that can consist of lime for additional hardening or seeds or seedlings of vines, grass, creeping plants, or other plants, moss, or fungus for biologically strengthening the structure or improving the aesthetics of the structure with growth of the organisms.

[0058] In yet another aspect, a method of creating permanent solid dome structures of regolith naturally present at the construction site, comprising a) inflating a mold of a structure shaped like a dome with an inner shell that is air and water impervious, a balloon, and an outer shell that is sediment-impervious with an opening at the top; b) applying water to the naturally present regolith on the ground around the mold to suspend sediments from the regolith in the water; c) continuously pumping the water with the suspended sediments into the opening in the outer shell at the top of the mold such that the sediment-laden water enters the space between the balloon and outer shell and such that the sediments settle within the space and water overflows from the opening at the top of the mold until the mold fills with sediment; d) optionally controlling the flow rate of water pumped into the mold to control the size, shape, and density of sediment entering the mold and rate of water and sediment entering the mold; e) optionally applying and controlling kinetic energy to the water in the mold by rapidly expanding and contracting air pressure in the balloon of the mold with an air pump that vibrates the balloon at constant or varying frequencies or applying sound waves with a sound speaker at constant or varying frequencies from within the balloon of the mold to control the size and density of sediment settling within the mold, rate of settling of sediment in the mold, rate of dewatering/drying of sediment in the mold, and density and compaction of settled sediment within the mold; f) optionally maintaining consistency of the dome shape and size while being filled with sediment with use of laser sensors monitoring distances within the balloon so that air pressure from an air pump is applied as needed to control air pressure in the balloon for the purpose of ensuring the mold’s size and shape through changing conditions, including day/night temperature and ambient air pressure changes; g) removing the outer shell of the mold from the top of the dome to the bottom as the sediment dries; h) optionally applying electrical current or heat to the outer surface of the sediment as it dries to control rate of drying and hardening of the sediment; i) deflating the balloon and removing the mold, thereby having created a dome structure, is provided herein; j) optionally applying electrical current or heat to the inner surface of the sediment as the balloon deflates to control rate of drying and hardening of the sediment from the top of the dome to the bottom of the dome; and k) optionally applying amendments to the regolith sediment material that is added to the mold that can consist of lime for additional hardening or seeds or seedlings of vines, grass, creeping plants, or other plants, moss, or fungus for biologically strengthening the structure or improving the aesthetics of the structure with growth of the organisms.

[0059] Numerous embodiments are further provided that can be applied to any aspect of the present disclosure described herein. For example, in some embodiments, the flow rate of sediment-laden water into the mold is constant. In some embodiments, the flow rate of sediment-laden water into the mold is varied and modulates sediment size during deposition of sediment, such as to have sediment size increase toward the base of the structure and decrease toward the top of the structure, or to accelerate the rate of sediment deposition into the mold when time is a critical factor. In some embodiments, water, sand, or mud is poured or scooped into the mold by hand with shovels or buckets. In some embodiments, water or sediment-laden water is added to the mold by a tube or tubes through which the water is pumped with a water pump or pumps. In some embodiments, vibratory energy is added to the mold with the rapid expansion and contraction of the balloon with one or more air pumps, or with sonic energy from sound speakers, or with vibrators attached to the exterior of the mold. In some embodiments, a heater is established inside the balloon to warm the water in the mold to accelerate sediment deposition in the mold. In some embodiments, even and consistent drying or hardening of the building material is facilitated by leaving the exterior shell in place during drying. In some embodiments, the mold is such that the resulting dome structure is elongated vertically, with the vertical height of the resulting structure being greater than the radius of its base. In some embodiments, the mold is such that the resulting dome structure is shortened vertically, with the vertical height of the resulting structure being less than the radius of its base.

[0060] In some embodiments, the exterior height of the resulting dome structure is between approximately 1 foot and approximately 500 feet. [0061] In some embodiments, the radius of the exterior base of the dome structure is between approximately 1 foot and approximately 500 feet.

[0062] Exemplary Devices of the Present Disclosure

[0063] As described above, embodiments are applicable to any device described herein. In some embodiments, a mobile battery-powered, generator-powered, or A/C wall outlet- powered device for constructing dome building structures enables a single person to construct a dome structure by inflating a dome building structure mold, enabling the person to add building material to the mold, and then removing the mold. In some embodiments, the building material is added by hand and consists of water, wet sand, or mud. In some embodiments, the building material is added to the mold by one or more pumps and consists of sediment from a water body, regolith from the construction site or area around the construction site, or commercially available clay or concrete.

[0064] In some embodiments, a device, comprising a) an inflatable balloon that inflates to a dome shape comprising the inside layer of a mold for a dome structure and with a valve for holding air pressure, connecting an air pump, and deflating the balloon; b) a water-impervious material loosely fitting over the outside surface of a) and connected to a) at its base at ground level comprising the outside layer of the dome structure mold with an opening at the top into which water is added and with water-sealed zippers extending vertically for opening and closing the mold; and c) a detachable air pump for inflating a).

[0065] In some embodiments, an inflatable balloon that inflates to a dome shape comprising the inside layer of a mold for a dome structure and with a valve for holding air pressure in the balloon, connecting an air pump, and deflating the balloon. In some embodiments, a sediment-impervious material loosely fitting to the outside surface of the balloon and connected to the balloon at its base at ground level comprising the outside layer of the dome structure mold with an opening at the top into which sand or mud is added and with water- sealed zippers extending vertically for opening and closing the mold. In some embodiments, a detachable air or water pump for inflating the balloon.

[0066] In another aspect, a device, comprising a) an inflatable balloon that inflates to a dome shape comprising the inside layer of a mold for a dome structure and with one or more valves for holding air pressure in the balloon, connecting to an air pump, and deflating the balloon; b) a water-impervious material loosely fitting to the outside surface of a) and connected to a) at its base at ground level comprising the outside shell of a dome structure mold with an opening at the top into which sediment-laden water is added and with water-sealed zippers extending vertically with weighted strings attached to zipper levers for closing and opening the exterior of the dome structure mold; c) one or more detachable air pumps for inflating a); d) one or more tubes along the outside of b) extending from approximately ground surface or further to the opening in b) and connected to water pumps for pumping sediment-laden water, or clay and water mixture, or concrete and water mixture into the mold formed by a) and b); e) a water hose spraying the ground or filling and moving in a circular motion water along the ground or in a dug out moat or temporary pond to create the sediment-laden water supplied into d).

[0067] In yet another aspect, a device, comprising a) an inflatable balloon that inflates to a dome shape comprising the inside layer of a mold for a dome structure and with one or more valves for holding air pressure in the balloon, connecting to an air pump, and deflating the balloon; b) a water-impervious material loosely fitting to the outside surface of a) and connected to a) at its base at ground level comprising the outside layer of a dome structure mold with an opening at the top into which sediment-laden water is added and with water- sealed zippers extending vertically with weighted strings attached to zipper levers for closing and opening the exterior of the dome structure mold; c) one or more detachable air pumps for inflating a); d) one or more tubes along the outside of b) extending from approximately ground surface or further to the opening in b) and connected to one or more water pumps for pumping sediment-laden water, or clay and water mixture, or concrete and water mixture into the mold formed by a) and b); e) a water hose spraying the ground or filling and moving in a circular motion water in a dug out moat around the mold to create the sediment-laden water supplied into d); f) up to one or more laser linear distance measurement sensors placed at the center inside of the balloon at ground level to monitor the distance from the sensor to at least one point along the inside of the inflated balloon; g) up to one or more detachable air pumps to modulate air pressure within the balloon to maintain consistency of the mold’s structure based on information provided by f); h) up to one or more sound speakers placed on the ground at the center inside a) to produce sound waves at a constant frequency or varying frequencies against the interior walls of a) and remotely operated; i) up to one or more vibrators located along the interior of a) or exterior of b) to provide vibrations to the mold at a constant frequency or varying frequencies; j) up to one or more heaters located inside a to increase water temperature to accelerate sediment deposition and to accelerate drying of sediment; k) up to one or more high-temperature heating mechanisms to sinter building material after the material is deposited and settled in the mold; 1) up to one or more fans placed at ground level blowing material toward the mold while it deposition is occurring or during drying.

[0068] In yet another aspect, a device, comprising a) an inflatable balloon that inflates to a dome shape comprising the inside layer of a mold for a dome structure and with one or more valves for holding air pressure in the balloon, connecting to a water pump, and deflating the balloon; b) a water-impervious material loosely fitting to the outside surface of a) and connected to a) at its base at ground level comprising the outside layer of a dome structure mold with an opening at the top into which sediment-laden water is added and with water- sealed zippers extending vertically with weighted strings attached to zipper levers for closing and opening the exterior of the dome structure mold; c) one or more detachable water pumps for inflating a); d) one or more tubes along the outside of b) extending from approximately seafloor surface or further to the opening in b) and connected to one or more water pumps for pumping sediment-laden water, or clay and water mixture, or concrete and water mixture into the mold formed by a) and b); e) a water hose spraying the seafloor to create the sediment-laden water supplied into d); f) up to one or more sound speakers placed on the ground at the center inside a) to produce sound waves at a constant frequency or varying frequencies against the interior walls of a) and remotely operated; g) up to one or more vibrators located along the interior of a) or exterior of b) to provide vibrations to the mold at a constant frequency or varying frequencies; h) up to one or more heaters located inside a to increase water temperature to accelerate sediment deposition and to accelerate drying of sediment; i) up to one or more air pumps to pump air into the dome building structure; and j) up to one or more high-temperature heating mechanisms to sinter building material after the material is deposited and settled in the mold.

[0069] Fig. 1 illustrates a cross-section of a self-constructing structure 100 having a dome shape according to an embodiment of the present disclosure. As illustrated in Fig. 1, the self constructing structure 100 includes an outer shell 102 and an inflatable inner balloon 104. In some embodiments, the outer shell 102 may be made from a rigid material. In some embodiments, the outer shell 102 may be made from a flexible material. In some embodiments, the outer shell 102 may be made from two or more components that fit together to thereby form the complete shell. In various embodiments, the outer shell 102 may include a zipper for fast assembly or disassembly. The inner balloon 104 is generally made from any suitable material as is known in the art, such as, for example, a polymer. In various embodiments, the polymer may include vinyl and/or polyethylene. In various embodiments, the inner balloon 104 includes strands of material reinforcing the balloon such that it can be inflated to higher air pressures for greater rigidity. In some embodiments, the reinforcing material (e.g. strands) can be woven or integrated into the balloon material. In various embodiments, a net may be positioned on the balloon to thereby secure the balloon in place and/or reinforce the balloon to allow for a higher inflation pressure. In various embodiments, the net is anchored to the ground around the base circumference of the balloon. In various embodiments, the net is secured via corkscrew anchors and/or stakes. In various embodiments, the net has a dome shape.

[0070] When the inner balloon 104 is inflated by a compressor (e.g., air pump) 108 connected to the inner balloon 104 via a tube 109, a gap 105 is formed between the inner balloon 104 and the outer shell 102. In some embodiments, the inner balloon 104 and outer shell 102 may be substantially in contact when the inner balloon 104 is inflated and, once water and material is added into the interface therebetween, the gap 105 forms as the inner balloon 104 and outer shell 102 separate from one another.

[0071] The structure 100 further includes an opening 106 at the top (i.e., the apex) of the outer shell 102. The opening 106 provides access to the gap 105 (or interface) between the inner balloon 104 and the outer shell 102 to facilitate the addition of building material into the gap 105. The opening 106 is fluidly connected by a tube 110 to a pump 112 configured to pump a building material 114a from a source 115 (e.g, a moat) in close proximity to the construction site of the structure 100. In some embodiments the circular opening 106 is a rigid hoop with leveling sensors that wirelessly transmit data about the hoop’s orientation; in response to the leveling data, the hoop is centered at the apex with ropes connected to the hoop 106. In some embodiments, the building material 114a may include water (e.g, water from melting snow or ice), mud, clay, concrete, a water-sediment mixture, and a water-sand mixture. In some embodiments, the building material 114b (e.g, water) pumped into the gap 105 may be allowed to freeze to thereby form a solid structure 100. In some embodiments, a heater 116 may be used to heat the building material 114a. In various embodiments, the mold may include a liner disposed within the gap. In various embodiments, the liner is made of a flexible and/or water-impervious material. In various embodiments, the liner includes an apex and an opening positioned at the apex that aligns with the opening of the outer shell. In various embodiments, the liner is configured to line the gap and contain the water and/or construction material. In various embodiments, the liner is reusable. In various embodiments, the liner is disposable. In various embodiments, the shell includes a net anchored to the ground. In various embodiments, the net is anchored to the ground around the base circumference of the net. In various embodiments, the net has a dome shape.

[0072] Fig. 2 illustrates a cross-section of a self-constructing structure 200 having a dome shape according to an embodiment of the present disclosure. The self-constructing structure 200 of Fig. 2 is substantially similar to the structure 100 of Fig. 1 and includes an outer shell 202 and an inflatable inner balloon 204. When the inner balloon 204 is inflated by a compressor ( e.g ., air pump) 208 connected to the inner balloon 204 via a tube 209, a gap 205 is formed between the inner balloon 204 and the outer shell 202. In some embodiments, the inner balloon 204 and outer shell 202 may be substantially in contact when the inner balloon

204 is inflated and, once water and material is added into the interface therebetween, the gap

205 forms as the inner balloon 204 and outer shell 202 separate from one another. The gap may be larger at the bottom than it is near the opening at the apex. In various embodiments, the balloon may include a net as described above. In various embodiments, the gap may include a liner as described above.

[0073] The structure 200 further includes an opening 206 at the top (i.e., the apex) of the outer shell 202. The opening 206 is fluidly connected by a tube 210 to a pump 212a configured to pump a building material 214a from a source 215 (e.g., a moat) in close proximity to the construction site of the structure 200. In some embodiments, the building material 214a may include water ( e.g ., water from melting snow or ice), mud, clay, concrete, a water-sediment mixture, and a water-sand mixture. In some embodiments, the heater 216 may be used to heat the structure 200, for example, to solidify or evaporate water from the building material 214b that has been pumped in the gap 205. In some embodiments, if the building material 214a is a slurry or mixture (e.g., water-sand mixture), the solid particles (e.g, sand) may settle to the bottom of the structure 200 thereby forming a substantially solid portion. In some embodiments, excess water from a mixture (e.g, a water-sand mixture) pumped into the gap 205 may pour out of the opening 206 as the solid particles settle and form the substantially solid structure 200. In various embodiments, the shell may include a net as described above.

[0074] In various embodiments, one or more additional pumps 212b-212c may be included in the moat to pump building material 214a from the source 215 into the opening 206. In various embodiments, one or more additional pumps 212d may be included within the source 215 to mix (either continuously or periodically) the building material 214a. Water pumps 212d may be used where the building material 214a is a slurry or mixture to keep the solid particles suspended in solution and prevent the solid particles from settling to the bottom of the source 215. If used in a moat, the pumps may be evenly spaced within the moat toward the moat’s exterior to create and maintain circular water flow in the moat. In various embodiments, one or more pumps 212e may be used to supply the source 215 with additional building material and/or specific components of the building material 214a, such as, for example, water. In various embodiments, one or more fans 218 may be used to blow material into the source 215.

[0075] In various embodiments, one or more vibration sources 220 may be disposed on the outer shell 202 to vibrate the structure 200 and promote settling of the solid particles comprising the building material 214b. In various embodiments, one or more sources of sonic energy ( e.g ., sound speakers) 222 may be placed in the balloon 204. The sources of sonic energy 222 may promote settling of the solid particles comprising the building material

214b

[0076] Figs. 3A-3B illustrate various cross-sections of a self-constructing structure 300 having a dome shape according to an embodiment of the present disclosure. Similar to the above figures, the structure 300 includes an outer shell 302, an inner balloon, 304, and a building material 314 disposed in the gap created between the inner balloon 304 and the outer shell 302. In various embodiments, the outer shell 302 may be a net having a dome shape. In various embodiments, the structure 300 includes a net on the outer surface of the balloon 304 configured to secure the balloon 304 and/or reinforce the balloon 304 to allow for higher inflation pressures. In various embodiments, the net 322 has opening sizes of 0.01mm to 100mm. In various embodiments, the net 322 may be made of a polymer, such as, for example, polyethylene, ultra-high molecular weight polyethylene, polyamide, polypropylene, polyethylene terephthalate, and/or polyvinyl chloride. In various embodiments, the net 322 and/or the outer shell 302 may be secured to the ground via an anchor 324. In various embodiments, the anchor 324 may be a corkscrew anchor or a stake. In various embodiments, the structure 300 may include a liner 326 configured to line the gap in which the building material 314 is pumped.

[0077] Fig. 4 illustrates a cross-sectional exploded view of a self-constructing structure 400 having a dome shape according to an embodiment of the present disclosure. Similar to Figs. 3A-3B, the structure 400 includes an outer shell 402, inner balloon 404, a net 422, disposed on the outer surface of the balloon 404, a liner 426 disposed within the gap between the outer shell 402 and the inner balloon 404, and anchors 424 anchoring the net 422 (and, in some embodiments, the outer shell 402, which may be a net) to the ground. In various embodiments, the liner 426 and the outer shell 402 both include an opening 406 at the apex that align when assembled together.

[0078] Fig. 5 illustrates a flow diagram of a method 500 for manufacturing a self- constructing structure having a dome shape according to an embodiment of the present disclosure. At 502, a mold is provided including an inflatable inner balloon and a non- inflatable outer shell coupled to the inner balloon about a base circumference, the outer shell having an apex and an opening disposed at the apex. At 504, the inner balloon is inflated to form a gap between the inner balloon and the outer shell. At 506, building material is added into the opening of the outer shell thereby filling the gap with the building material. At 508, the outer shell is removed. At 510, the inner balloon is deflated. At 512, the inner balloon is removed.

[0079] Exemplary Embodiments

[0080] Example 1 : Self-Constructing Ice Dome

[0081] In this example, a camper is in a cold environment in which day and nighttime ambient temperatures are sub-freezing. The camper carries a portable, battery-powered device to self-construct an ice dome for use as a temporary domicile. The device is comprised of a portable inflatable dome structure mold, an air pump to inflate the mold, a small heater unit, and a water pump and tubes. The camper removes the device from a backpack and inflates the mold, which when inflated has a height of 7 feet and base that is 14 feet wide at the base. While the mold is inflating, the camper applies the heater unit to ice and snow on the ground to melt the ice and snow into liquid water. The water pump and tubes are arranged to pump the liquid water into the inflated mold. Once the mold is filled with water, the camper waits until the water in the mold freezes. Next, the camper removes the outer shell of the mold by unzipping it, and deflates and removes the inner shell. The camper then cuts an opening in the frozen ice dome structure to use as a doorway. The inflatable mold is folded or rolled and the device components returned to the backpack.

[0082] Example 2: Self-Constructing Airplane Hangar

[0083] In this example a builder constructs a 30-ft tall, 60-ft wide (at its base) hangar at a remote airfield for storing his small airplane. The builder has selected a relatively flat location free of trees or shrubs near the runway and next to a small lake. The builder arrives with a small truck containing the device, which is powered by diesel or gasoline powered generators. The builder drives to the center location of the hangar and unrolls the inflatable mold from the truck, unfolding it and spreading it across the construction site in a circle with diameter of 60 ft. The builder adds tubes to the dome and partially inflates it with an air pump. The builder unzips an airtight zipper and enters the partially inflated balloon, where he establishes at its center on the ground an electric wirelessly operated heater, wirelessly operated sound speaker, and wirelessly operated laser measure and thermometer with extension cord fed to one of the generators. The builder closes the entry way airtight zipper and completes inflating the balloon mold with the air pump.

[0084] While the balloon mold is inflating the builder connects a hose to a water pump and begins pumping water from the lake. Water from the lake is sprayed at high velocity and volume to the ground around the balloon mold, water blasting a small indentation (moat) around the mold of depth of less than 3 ft. and width of less than 6 ft. The builder sets up six water pumps around the moat that pump the muddy water of the moat in a circular direction, thereby creating water flow that suspends sediments from the regolith into the moving water. The builder attaches the tubes to water pumps and the tubes entering the opening in the mold. In various embodiments, a net may be positioned over the balloon. In various embodiments, the outer shell may be a net. In various embodiments, each net may be anchored to the ground via anchors. In various embodiments, a water impervious liner may be disposed in the gap between the outer shell and the inner balloon. In various embodiments, the liner may include an opening at the apex of the liner. In various embodiments, the opening of the liner may be aligned with the opening in the outer shell.

[0085] When the balloon (inner shell of the mold) has finished inflating and is rigid with air pressure, the builder turns on the heater, sound speaker, and laser measure. The builder turns on the water pumps and begins filling the mold with the sediment-laden water from the moat, turning on the air pump as needed to add or reduce air pressure of the balloon to maintain its structural shape and consistency based on data provided by the laser measure. Once the mold has filled with water, the outer shell of the mold becomes rigid with water pressure. Once the mold has filled with water, water begins overflowing from the top of the mold down the sides of the outer shell and returns to the moat where it replenishes the water in the moat. Water from the system ultimately re-enters the lake after running across the ground and being filtered of sediment by vegetation or by returning to the underground water table. Sediments from the sediment-laden water enter the mold and settle to the bottom of the mold as the velocity of the water decreases with increased volume of water downward into the mold. The builder accelerates the settling of sediment by turning on the heater in the balloon, which warms the air and water in the balloon. The builder further accelerates the settling of sediment in the mold, prevents sediment from sticking to the sides of the mold before it settles at the bottom of the mold, and improves the compaction and drying of the sediments settling in the mold, by inputting vibratory kinetic energy into the mold. The vibratory kinetic energy is applied by turning on vibrators located across the interior (non-wet) surface of the balloon and by turning on the speaker within the balloon. The vibrators and speaker oscillate between different frequencies, further accelerating the settling of sediments.

[0086] The builder further feeds sediment into the moat by spraying water across the ground with the hose toward the moat, sending mud into the moat. The builder further feeds building material toward the moat by turning on fans that switch all at once at intervals between oscillating mode (swinging back and forth like a general oscillating home or desk fan, and generally directed toward the moat) and a fixed mode in which all the fans blow material in slightly circle motion around and toward the moat.

[0087] As the mold fills with sediment and water volume within the mold decreases, the builder slows the water pumps to slow the velocity of water entering and exiting the mold so that sediment continues to deposit in the mold. Once the mold has filled with sediment, the builder turns off all water pumps. The heater, sound speaker, and vibrators continue to operate while the sediment settles within the mold to add thermal and kinetic energy that accelerates dewatering and improves compaction. After a period of time, the builder turns on the water pumps again to add more sediment to the top of the mold to ensure it is filled with sediment while keeping the heater, sound speaker, and vibrators operating. This on/off sequence of water application may occur several more times until the mold is completely filled with compacted sediment. The sediment continues to dewater and dry while the mold is still in place, allowing the water to evaporate from the top of the mold. A cover may be applied over the opening of the mold to prevent water infiltration from rain events. The sound speaker and vibrators are turned off while heat from the heater continues to be applied to accelerate drying.

[0088] After a period of time, when the building material has sufficiently dried, the builder removes the outer shell of the mold by unzipping zippers located vertically along the sides of the outer shell. In various embodiments, the zippers may be watertight. The building material continues to dry with the heater turned on. After the building material has sufficiently dried, the balloon is slowly deflated. The builder then cuts an opening in the side of the dome structure, unzips the partially deflated balloon, enters the balloon and removes the heater, sound speaker, and laser measure. In various embodiments, where a net is used, the anchors securing the net(s) and the net may be removed after the building material has dried. In various embodiments, where a liner is used, the liner may be removed after the building material has dried

[0089] Next, the builder enters the dome structure and removes the balloon. The builder then establishes a propane or natural gas heater around the interior of the dome. The heater is ignited and gradually and evenly raises the temperature of the dome to an interior temperature exceeding 600F. The temperature is maintained until the building material is sufficiently sintered to the desired strength. The builder then lowers the heat gradually, removes the heater, and applies any additional treatments (e.g., paint) and modifications (e.g., cutouts for windows or doors) as desired.

[0090] All publications, patents, and patent applications mentioned herein are hereby incorporated by reference in their entirety as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference. In case of conflict, the present application, including any definitions herein, will control.

[0091] The flowchart and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present disclosure. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In various alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.

[0092] The descriptions of the various embodiments of the present disclosure have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.

Claims

What is claimed is:

1. A mold for forming a structure comprising:

an inflatable inner balloon comprising a dome shape;

a non-inflatable outer shell coupled to the inner balloon about a base circumference, the outer shell having an apex and an opening disposed at the apex; and

a pump in fluid communication with the opening of the outer shell; wherein, when the inner balloon is inflated, a gap is formed between the inner balloon and the outer shell for containing a building material, and the outer shell comprises a dome shape.

2. The mold of claim 1, further comprising a building material disposed between the inner balloon and outer shell.

3. The mold of claim 2, wherein the building material is selected from the group

consisting of water, mud, clay, concrete, a water-sediment mixture, and a water- sand mixture.

4. The mold of claim 2, wherein the building material comprises an additive selected from the group consisting of: lime, cement, and a biologically-based material.

5. The mold of claim 4, wherein biologically-based material comprises seeds, vines, grass, plants, moss, or fungus.

6. The mold of claim 1, wherein the outer shell comprises a flexible material.

7. The mold of claim 1, wherein the outer shell comprises a rigid material.

8. The mold of claim 1, wherein the outer shell is removable.

9. The mold of claim 8, wherein the outer shell comprises a zipper.

10. The mold of claim 8, wherein the outer shell comprises a plurality of partitions.

11. The mold of claim 1, further comprising a tube extending from the opening of the outer shell, wherein the pump is in fluid communication with the tube.

12. The mold of claim 1, wherein the pump is one of a plurality of pumps in fluid

communication with the opening.

13. The mold of claim 1, further comprising a vibration mechanism disposed on an exterior of the mold.

14. The mold of claim 1, further comprising a sound speaker for application of sonic energy to the mold.

15. The mold of claim 1, further comprising a heater.

16. The mold of claim 1, further comprising one or more laser sensors configured to measure a size and a shape of the inner balloon by adjusting a flow of air from one or more air pumps in fluid communication with the inner balloon.

17. The mold of claim 1, further comprising a pressure gauge configured to measure air pressure within the inner balloon.

18. The mold of claim 1, further comprising a net having a dome shape and disposed around the inner balloon.

19. The mold of claim 18, wherein the net is secured to ground via anchors selected from the group consisting of: corkscrew anchors and stakes.

20. The mold of claim 1, wherein the outer shell comprises a net having a dome shape.

21. The mold of claim 20, wherein the net is secured to ground via anchors selected from the group consisting of: corkscrew anchors and stakes.

22. The mold of claim 1, further comprising a liner conforming to the gap between the inner balloon and outer shell, the liner having an apex and an opening at the apex, the opening of the liner being aligned with the opening of the outer shell.

23. The mold of claim 22, wherein the liner comprises a flexible material.

24. The mold of claim 22, wherein the liner comprises a water-impervious material.

25. The mold of claim 22, wherein the liner is reusable.

26. The mold of claim 22, wherein the liner is disposable.

27. A method of forming a structure, the method comprising:

providing a mold comprising an inflatable inner balloon comprising a dome shape and a non-inflatable outer shell coupled to the inner balloon about a base circumference, the outer shell having an apex and an opening disposed at the apex;

inflating the inner balloon to form a gap between the inner balloon and the outer shell;

adding building material into the opening of the outer shell thereby filling the gap with the building material;

removing the outer shell;

deflating the inner balloon; and

removing the inner balloon.

28. The method of claim 27, further comprising forming a trench around the mold and filling the trench with water.

29. The method of claim 27, further comprising forming a temporary pond and filling the pond with water.

30. The method of claim 27, wherein the building material is selected from the group consisting of water, mud, clay, concrete, a water-sediment mixture, and a water- sand mixture.

31. The method of claim 30, wherein the building material comprises an additive

selected from the group consisting of: lime, cement, and a biologically-based material.

32. The method of claim 31, wherein the biologically-based material comprises seeds, vines, grass, plants, moss, or fungus.

33. The method of claim 27, wherein adding building material comprises pouring or scooping building material into the opening.

34. The method of claim 27, further comprising disposing a tube within the opening and pumping the building material into the tube.

35. The method of claim 27, wherein while material is pumped into the mold excess water continuously overflows from the opening in the mold, runs down the exterior surface of the outer shell of the mold, and is re-circulated carrying building material back into the mold with the tubes and pumps while building material settles in the mold.

36. The method of claim 27, further comprising heating the building material.

37. The method of claim 27, further comprising applying sonic energy to the building material.

38. The method of claim 27, further comprising applying vibrational energy to the building material.

39. The method of claim 27, further comprising varying a pressure inside the inflatable balloon.

40. The method of claim 27, wherein pumping comprises varying the flow rate of the building material over time.

41. The method of claim 27, further comprising directing one or more laser sensors at the inner balloon, the one or more laser sensors configured to measure a size and a shape of the inner balloon by adjusting a flow of air from one or more air pumps in fluid communication with the inner balloon.

42. The method of claim 27, further comprising coupling a pressure gauge to the inner balloon, the pressure gauge configured to measure air pressure within the inner balloon.

43. The method of claim 27, further comprising a net having a dome shape and disposed around the inner balloon.

44. The method of claim 43, wherein the net is secured to ground via anchors selected from the group consisting of: corkscrew anchors and stakes.

45. The method of claim 27, wherein the outer shell comprises a net having a dome shape.

46. The method of claim 45, wherein the net is secured to ground via anchors selected from the group consisting of: corkscrew anchors and stakes.

47. The method of claim 27, further comprising positioning a liner within the gap

between the inner balloon and outer shell, the liner having an apex and an opening at the apex, the opening of the liner being aligned with the opening of the outer shell.

48. The method of claim 47, wherein the liner comprises a flexible material.

49. The method of claim 47, wherein the liner comprises a water-impervious material.

50. The method of claim 47, wherein the liner is reusable.

51. The method of claim 47, wherein the liner is disposable.