Dynamic flexible extruding building method and apparatus and construction material used therewith

Abstract

A building structure that is a one-piece extruded building that can simultaneously build inner and outer walls, roof, reinforcement and optionally even floors. Said structure is made up as a composite of an inner and outer encapsulating building material that provides structural strength, plus an inner core material composed of a highly expanding closed cell foam material for insulation. The building material is polymer based, but can also be a polymer-concrete, wherein traditional fibers are minimized and substituted for other aggregates. The polymer in the encapsulating material can have the catalyst encapsulated and premixed into a slurry form activated at the injection point by mechanically rupturing the capsule, or can be mixed and added at the injection point with a specially designed metering injectors. All comers and joints allow the encapsulating building material to join between inner/outer walls forming columns and evenly spaced beams or studs made from the same encapsulating building material. This system of construction can reduce the construction time to a matter of hours what would normally take days, weeks, or months according to the structure and is built by pumps while allowing for mass production and sizeable cost reductions.

We claim:  
     
         1 . A method for forming a structure comprising the steps of: 
 movably connecting a mold system to a guide frame including at least one inlet and at least one outlet;    injecting a curable polymeric material into the at least one inlet; and    moving the mold system along the guide frame at a rate sufficient for the polymeric material to cure sufficiently to maintain its shape as defined by the mold system to form an extruded structure including structural elements.    
     
     
         2 . The method of  claim 1 , further comprising the step of: erecting the guide frame including a plurality of guide members defining a path.  
     
     
         3 . The method of  claim 1 , where in the mold system comprises a plurality of mold sections, where each mold section defines an extrudate profile and includes a closed end having at least one inlet and an open end defining a part of the at least one outlet.  
     
     
         4 . The method of  claim 1 , further comprising the step of: 
 periodically interrupting the injection of the curable polymeric material to form openings in the extruded structure.    
     
     
         5 . The method of  claim 1 , wherein the polymeric material comprises at least one thermal setting resin.  
     
     
         6 . The method of  claim 1 , wherein the polymeric material comprises at least one thermal setting resin and at least one filler.  
     
     
         7 . The method of  claim 1 , wherein the polymeric material comprises at least one thermal setting resin, at least one filler, and at least one reinforcing fiber.  
     
     
         8 . The method of  claim 1 , wherein the polymeric material comprises at least one thermal setting resin, at least one filler, at least one reinforcing fiber and at least one catalyst.  
     
     
         9 . The method of  claim 3 , further comprising the step of: 
 repositioning the guide inside or outside a portion of the structure;    movably connecting at least one mold section to the repositioned guide;    injecting the polymeric material into the mold section; and    moving the mold section to form an inner or outer element of the structure.    
     
     
         10 . The method of  claim 1 , wherein the structure comprises straight structural elements.  
     
     
         11 . The method of  claim 1 , where in the structure comprises straight and/or arcuate or curvilinear structural elements.  
     
     
         12 . An apparatus for forming an extruded structure comprising: 
 a guide frame including a plurality of posts defining a path; and    a mold system movably connected to the guide frame, where the mold system comprises an open end defining an extrudate profile and a closed end having at least one inlet connected to a source of a curable polymeric material, 
 where the mold system being movable along the path to extrude the curable polymeric material out of the open end to form the extrudate profile.  
   
     
     
         13 . The apparatus of  claim 12 , where in the mold system comprises a plurality of mold sections, where each mold section includes a closed end having at least one inlet and an open end defining a part of the extrudate profile.  
     
     
         14 . The apparatus of  claim 12 , wherein the mold system moves vertically to extrude a wall and horizontally to extrude a ceiling of the structure.  
     
     
         15 . The apparatus of  claim 12 , wherein the mold system moves horizontally to form a floor.  
     
     
         16 . The apparatus of  claim 12 , wherein the structure is residential structure.  
     
     
         17 . The apparatus of  claim 12 , wherein the structure is commercial structure.  
     
     
         18 . An extruded structure comprising: 
 continuous members comprising a curable polymeric material where the members are extruded in place.    
     
     
         19 . The structure of  claim 18 , wherein the members include openings therein.  
     
     
         20 . The structure of  claim 18 , wherein the openings are filled with a closed cell foam.