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Abstract

A multi-layered structure with improved stability and insulation is disclosed. Methods for making the multi-layered structure are also disclosed. The structure comprises layers of foam and layers of solid material which are sprayed onto each other via an industrial robot having spray nozzles. The layers of foam are sprayed onto a supporting structure of a building, and the process of spraying is such that each consecutively sprayed layer is initiated after only a short lag in time from the initiation of the previous layer. The structure comprises at least two layers (preferably at least three layers), each layer having different mechanical properties. The layers may further be reinforced with reinforcing fibers and/or fiber fragments. An additional layer of fibrous material may comprise outer and/or inner layers of the structure. The disclosed structure is built faster and has significantly higher load-bearing and insulative capacities than the state of the art.

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First Claim