US 3,961,002 AGranted

Method of building construction using synthetic foam material

OwnerClarence Eugene Browninventor

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Abstract

Method and apparatus for building construction wherein the building is formed as an integral unit of synthetic material. A first form means is provided which defines cavity portions representative of a building construction, walls and ceiling portions including predetermined utility component openings, window and door openings. Utility components including electrical environmental control and plumbing are positioned within the cavity portions of the first form means adjacent the predetermined utility component openings. Door and window frame means are positioned within the first form means adjacent the window and door openings. An additional form means is added to the first form means for effecting a substantially enclosed cavity portion representative of a pre-designed building. Means is provided for filling the enclosed cavity portions defined by the first form means and the additional form means with synthetic building material. After the enclosed form means have been filled with the synthetic building material, the material is allowed to set up sufficiently to assume the form of the enclosed cavity portions, after which the form means are removed to expose a building construction formed as an integral unit including upright walls and top portions having the utility components and window and door frames molded therein. The electrical and environmental control components are constructed as a preassembled packaged unit having a main control unit with input conduit means connected thereto and including a plurality of output conduits corresponding to the number of locations of output conduits required in the predesigned building. Means is provided for securing the utility components into position adjacent the openings provided in the form means and means is provided for securing the window and door frames in position in the form means prior to a forming operation.

A method of constructing a building, wherein the building is formed as an integral unit of synthetic material, comprising the steps of:

forming a mold unit according to a pre-determined design by positioning separate rigid, one-piece room units relative to one another so as to define a first set of cavities therebetween, said room units including tapered wall portions for facilitating easy removal of said building, and a first set of openings within said wall portions adjacent said cavities;
positioning door frame means within said first set of cavities adjacent said first set of openings within said wall portions, said door frame means including flange means which is provided with a series of openings;
positioning additional door frame means adjacent a second set of openings within exterior wall portions of said room units, said additional door frame means having flange means which is provided with a series of openings;
positioning window frame means adjacent a third set of openings within exterior wall portions of said room units, said window frame means having flange means which is provided with a series of openings;
positioning additional mold structures adjacent to said mold unit so as to form a second set of cavities between said structures and said unit, in which are disposed said additional door frame means and said window frame means;
filling said first and second set of cavities with a synthetic polyurethane foam building material such that said material respectively envelops said flange means, and respectively penetrates said openings within said flange means of said door frame means, said additional door frame means, and said window frame means, whereby said door frame means, said additional door frame means, and said window frame means will be securely anchored within said synthetic material when said material sets;
allowing said synthetic material to set;
and
removing said mold unit and said mold structures from said set synthetic material so as to expose a building which includes interior wall portions and interior door openings formed within said first set of cavities, and exterior wall portions, exterior door openings, window openings, and a roof portion formed within said second set of cavities.

6 more elements

Facts

Application

05/328,379Filed 31 Jan 1973 · continuation

Priority

19 Nov 1970

Granted

1 Jun 1976

Term ends

Not estimatedThe source records don’t support an estimate.

Classification7 codes

E04B 1/162
With vertical and horizontal slabs, both being partially cast in situ: with a central core, used as form, in order to form a continuous concrete shell
H02G 3/00
Installations of electric cables or lines or protective tubing therefor in or
H02G 3/121
For flush mounting: in plain walls
Y10S 264/83
Plastic and nonmetallic article shaping or treating: processes: injection molding of polyolefin-type foam

Abstract

Claims1