U.S. patent application number 11/811757 was filed with the patent office on 2007-12-06 for building block and system for manufacture.
Invention is credited to Raymond F. Sinclair.
Application Number | 20070277472 11/811757 |
Document ID | / |
Family ID | 38788519 |
Filed Date | 2007-12-06 |
United States Patent
Application |
20070277472 |
Kind Code |
A1 |
Sinclair; Raymond F. |
December 6, 2007 |
Building block and system for manufacture
Abstract
A compressed building block formed of a pre-mix of fly ash,
Class C type, are combined with various aggregates either ground
wood and/or chips, having maybe a small amount of Portland cement
added thereto, moisturized, and then either molded, extruded or
compressed in a press into the configuration of a block. Boron as a
mold retardant and an insecticide, may be added to the composition,
to provide the formed block with further beneficial attributes. The
blocks may be formed by a system for extruding such blocks from the
formulation, or they may be formed by means of a mold or hydraulic
or other press and pressed into the configuration of the desired
block, needed for the construction.
Inventors: |
Sinclair; Raymond F.;
(Treasure Island, FL) |
Correspondence
Address: |
Paul M. Denk
763 S. New Ballas Rd. S. 170
St. Louis
MO
63141
US
|
Family ID: |
38788519 |
Appl. No.: |
11/811757 |
Filed: |
June 12, 2007 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
11523228 |
Sep 19, 2006 |
|
|
|
11811757 |
Jun 12, 2007 |
|
|
|
11238934 |
Sep 29, 2005 |
|
|
|
11811757 |
Jun 12, 2007 |
|
|
|
10411551 |
Apr 10, 2003 |
|
|
|
11238934 |
Sep 29, 2005 |
|
|
|
60371441 |
Apr 11, 2002 |
|
|
|
Current U.S.
Class: |
52/605 |
Current CPC
Class: |
Y02W 30/97 20150501;
E04C 1/397 20130101; C04B 2111/00129 20130101; B28C 9/00 20130101;
Y02W 30/92 20150501; E04B 2/10 20130101; C04B 28/04 20130101; E04B
2002/0206 20130101; E04B 2/04 20130101; Y02W 30/91 20150501; C04B
28/021 20130101; E04B 2/06 20130101; C04B 28/021 20130101; C04B
7/02 20130101; C04B 18/24 20130101; C04B 40/0028 20130101; C04B
2103/30 20130101; C04B 2103/63 20130101; C04B 2103/67 20130101;
C04B 28/04 20130101; C04B 18/08 20130101; C04B 18/24 20130101; C04B
40/0071 20130101; C04B 2103/30 20130101; C04B 2103/63 20130101;
C04B 2103/67 20130101 |
Class at
Publication: |
052/605 |
International
Class: |
E04C 2/04 20060101
E04C002/04 |
Claims
1. The construction of a building block, said block being
fabricated from molding, extruding, or compressing the blocks into
a high strength, medium weight building block, said block
fabricated into a multi-sided integrated block, and molded from a
formulation of ingredients which when the ingredients are mixed
and, treated with water there occurs a pozzolanic reaction, the
mixture of ingredients including: class C fly ash in containing
calcium hydroxide and added in the range of about fifty percent
(50%) to ninety percent (90%) by weight of the mixed formulation,
ground cellulosic material or other aggregate material in the
fibrous or solid state and mixed in the formulation between about
ten percent (10%) to fifty percent (50%) by weight of the mixed
formulation, water added in the range of about ten percent (10%) to
about twenty percent (20%) by weight of the mixed formulation, and
whereby pressure in the range of about 200 psi to 600 psi is
applied to said mixed ingredient formulation after the pozzolanic
reaction commences to form the mixture into the block form.
2. The building block of claim 1 and including Portland cement,
added in the range of ten percent (10%) to twenty percent (20%) by
weight of the mixed formulation to furnish an increase pozzolanic
reaction to the ingredients when forming the building block.
3. The building block of claim 2 wherein said cellulostic material
is selected from ground wood, textile fiber, ground bamboo, rice
hulls, that are combined with either ground wood and/or chips, or
with fine sand, and having an amount of Portland cement added
thereto, water is added to moisturize the composition, and then the
composition is processed by one of extrusion or compression in a
press to form the configured block.
4. The building block of claim 4 and including the addition of one
or more fire retardant, and an insecticide, to make the block mold
resistant and resistant to deterioration by insects.
5. The building block of claim 3 and including said building block
having end walls, side walls, and a top and bottom wall, at least
one of said end walls and at least one of said top and bottom wall
having a tongue portion, and the other of said end wall, and the
other of said top and bottom wall having a groove, to accommodate
the insertion of another building block tongue therein during the
erection of a wall.
6. Construction of a building block, said block being fabricated
from molding or extruding into a high strength, light weight
building block, said block ingredients which when the ingredients
are mixed creates a pozzolanic reaction including: class C fly ash
in a range of about fifty percent (50%) to ninety percent (90%) by
weight of the mixed formulation, ground cellulosic material mixed
in the formulation between about ten percent (10%) to fifty percent
(50%) by weight of the mixed formulation, water added in the range
of about ten percent (10%) to about to about twenty percent (20%)
by weight of the mixed formulation, and whereby pressure in the
range of approximately 200 to 600 PSI is applied to said mixed
ingredient formulation and forms it into the block form.
7. The building block of claim 6 and including Portland cement,
added in the range of ten percent (10% to twenty percent (20%) by
weight of the mixed formulation to furnish binding to the
ingredients when forming the building block.
8. The building block of claim 7 wherein said cellulostic material
is selected from the group consisting of wood shavings, saw dust,
wood chips, beet sugar waste and sugar cane and pulverized
cardboard.
9. The building block of claim 8 and including boron, added in the
range of one-half percent (1/2%) to five percent (5%) by weight of
the mixed formulation to furnish fire retardancy and as a preventer
of insect infestation to the molded block.
10. The building block of claim 8 wherein additional pressure may
be applied to the mixed ingredient formulation up to approximately
3,000 psi.
11. The building block of claim 8 wherein silica fume is added to
the ingredient mixture.
12. The building block of claim 6 wherein a plasticizer is added to
the ingredient mixture in an amount about one-eight percent (1/8%)
to two percent (2%) by weight of the mixture.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation-In-Part of the
application having Ser. No. 11/238,934, which was filed on Sep. 29,
2005, which is a Continuation-In-Part application of the
non-provisional patent application having Ser. No. 10/411,551,
filed on Apr. 10, 2003, based upon provisional patent application
having Ser. No. 60/371,441, filed on Apr. 11, 2002, which is owned
by the same inventors.
BACKGROUND OF THE INVENTION
[0002] This invention relates principally to a building block, one
that is constructed, generally of waste material, such as fly ash,
and can be either extruded or compressed under pressure into the
fabrication of a building block for use for constructing buildings
or the like.
[0003] There are numerous building blocks that are available in the
art for use for the construction primarily of commercial and
industrial type of buildings, and even some of such blocks are used
for constructing residential homes, as known. For example, most of
these blocks are fabricated from concrete, poured into a form, left
to cure, and then removed, and allowed to dry, in preparation for
usage. Blocks of this type, generally of a concrete type block, can
be constructed to a variety of shapes.
[0004] Various prior art types of blocks, usually of the molded
type, can be seen in the prior patent to Haener, U.S. Pat. No.
5,822,939, identified as An Insulated Building Block System. The
patent to Putnam, U.S. Pat. No. 2,319,345, discloses another type
of Fabricated Building Block. The patent to Crespo, U.S. Pat. No.
4,514,949, shows an Interlocking System for Building Walls, and it
should particularly be noted that the shown block includes
openings, and through which reinforcing rods may locate, during
building fabrication. The patent to Schmall, U.S. Pat. No. 513,423,
discloses another form of Building Block. The patent to Sherwood,
U.S. Pat. No. 5,715,635, discloses a Building Block Unit and Method
of Manufacturing the Same. This includes an interlocking type of
feature that can hold the blocks together, even perhaps without
connecting mortar. The patent to Stenekes, U.S. Pat. No. 6,065,265,
shows A Corner and End Block for Interlocking Building Blocks
System.
[0005] The patent to Hancock, U.S. Pat. No. 3,355,849, shows a
Building Wall and Tapered Interfitting Blocks Therefore. Another
patent to Hancock, U.S. Pat. No. 3,936,989, shows an Interlocking
Building Type of Block That Can Be Fabricated into a Wall System,
even perhaps with or without the use of mortar. U.S. Pat. No.
4,126,979, to Hancock, shows another Interlocking Form of Building
Block.
[0006] The current invention is designed to provide for the
construction of a building block, by a variety of methods, but one
which utilizes extensively what are currently considered as waste
products, with Class-C fly ash the primary ingredient and other
fibrous materials, in the category of wood chips, textile waste,
rice hulls, straw, sugar cane, sugar beet, sugar waste lime, and
other fibrous material, or other such solids, not pulverized, to
add bulk and strength to the mixture
[0007] For example, the United States patent to Strabala, U.S. Pat.
No. 5,534,058, discloses a structural product fabricated from waste
materials, and its method of making the same. The product includes
as ingredients fly ash, cellulose-based material, and an adhesive
binder for holding these ingredients together. The patent states
that the composition is particularly useful for forming structural
products such as bricks, panels, roof shingles, studs, and the
like. More specifically, the patent defines that the structural
product, which may also be formed into blocks, comprises a
substantially homogeneous blend from seventy to eighty five percent
(70 to 85%) by weight of a Class C fly ash, or a mixture of Class C
fly ash and Class F fly ash. The mixture further includes about
fifteen to thirty percent (15 to 30%) by weight of a cellulose
based material, which can be pulp, wood, sawdust, pulverized
cardboard, or the like. The block further includes an adhesive
binder, which is categorized as an adhesive bindery emulsion, even
one which can be mixed with water to form a liquid, but preferably
the adhesive binder is defined as polyvinyl acetate, which can be
added to the composition as a polyvinyl acetate emulsion. To quote
Dr. Robert Sickler's definition of an adhesive, "adhesives use
surface attachments to bind two solids together, and it does not
form a new matrix through the identified reaction." In other words,
there is no reaction in the Strabala process or product. The
composition also includes an inner filler, and such material may
include lime, Class F fly ash, or bottom ash, up to about thirty
five percent (35%) by weight of the total weight of the
composition, but the original matrix is maintained. No
reaction.
[0008] The current invention likewise utilizes a fly ash as a
primary ingredient, but varies substantially from what is
identified in the Strabala patent, utilizing either a molding or
pressure application to form its composite blocks, for use for a
related purpose, and that is for building purposes.
[0009] Other prior art patents identifying the use of fly ash, as
an ingredient for forming insulating and ceramic materials, and the
like, include the United States patent to Sicka, U.S. Pat. No.
3,625,723, for Foamed Ceramic Comprising Fly Ash and Phosphoric
Acid. U.S. Pat. No. 1,608,562, to Melandri, defines the Manufacture
of Building Blocks, Slabs, Floors, Ceilings, Tiles, and the Like,
from a mixture of fibers and cementitious material, and hydrated
lime. The patent to Halwani, U.S. Pat. No. 5,504,211, describes a
Lightweight Block Containing Stabilized Wood Aggregates. The patent
to Riddle, U.S. Pat. No. 5,366,548, explains the use of Volcanic
Fly Ash and Kiln Dust Compositions, and a Process for Making
Articles Therefrom. The patent to Patterson, U.S. Pat. No.
5,350,451, explains a Building Material Made from Waste Paper and a
Method for Producing the Same. The patent to Wada, et al., U.S.
Pat. No. 5,154,771, explains a Hydraulic Inorganic Composition and
Molded Articles Thereof. The patent to Lempfer, et al., U.S. Pat.
No. 5,102,596, explains the Method of Producing Shaped Articles of
Fiber/Binder Mixtures. The patent to Elias, U.S. Pat. No.
5,048,250, shows another type of Building Block. The patent to
Vinson, et al., U.S. Pat. No. 4,985,119, shows a Cellulose
Fiber-Reinforced Structure. The patent to Baes, U.S. Pat. No.
4,840,672, explains that Lightweight Insulating Boards and Process
for Manufacturing the Same. The patent to Costopoulos, et al., U.S.
Pat. No. 4,659,385, shows a Building Material Manufacturing from
Fly Ash. The patent to Barrable, U.S. Pat. No. 4,132,555, explains
a Building Board. Finally, the patent to Nutt, U.S. Pat. No.
3,753,749, shows other Concrete Compositions.
SUMMARY OF THE INVENTION
[0010] This invention relates primarily to the construction of a
unique building block, one fabricated totally from waste materials,
and a number of systems by which the block may be fabricated and
molded, into a high strength, lightweight finished product.
[0011] Essentially, the concept of this invention is to utilize a
fly ash, specifically of the class C type, and which may or may not
include elements of slag, or silica fume, all of which include the
ingredient calcium hydroxide, CH, which when mixed with silica, in
the presence of water, initiates a pozzolanic reaction and
activity, wherein the calcium hydroxide is said to have what are
identified as pozzolans that contain a morphecilica which is
sufficient when reacted with silica in the presence of water to
combine with the calcium hydroxide to form a calcium silicate
hydrate, C-S-H, combination. This is particularly true when the
pozzolan is combined with cement, such as Portland cement, and
during hydration, causes this pozzolanic reaction that binds the
materials together into the highly cementitious C-S-H composition.
The final product is a completely new reacted matrix. This reaction
holds the materials together into a highly cementitious C-S-H
composition. This is the basis for formation of this unique
building block when the formulation is exposed to moderate
pressure.
[0012] As is well known, the only source for this Calcium Hydroxide
is from the Class C fly ash or Portland cement, as known. It mixes
with the silicates, in the presence of water, it does form a
chemical reaction that combines into the formula C-S-H.
[0013] It is also been found that utilizing high compression upon
these types of ingredients works negatively on the hardening
process as the blocks are formed. Thus, the only pressure that is
utilized in this development is a lower pressure, and just enough
to cause the slurry to form and conform to the die pattern.
[0014] Once the fifty percent (50%) to ninety percent (90%) fly ash
is in the mixture, it does not really matter what aggregate is
added to the composition, but in the Preferred Embodiment it is the
fibrous material, and some small aggregate, not pulverized, that
provides best formation of the blocks and to allow the water, when
mixed, to achieve that pozzolanic reaction. It changes the Calcium
Hydroxide into the highly cementious calcium silica hydroxide,
which does get hard on its own.
[0015] The aggregates can be defined as fibrous, or solids. The
fibrous material is a ground fibrous material, not pulverized and
which may be wood chips, textile waste, bamboo, sugar cane, beet
sugar residue, rice hulls, straw, and related types of fibrous
materials. When formed into the blocks, they function as hard wood,
and in that condition, can accept screws, nails, can be sawed,
drilled, and even cut with a router.
[0016] Other solids like sugar beet waste lime, sea shells, sand,
gravel, etc., while they do not accept screws or nails, do function
to provide hardness to the block when formed. These aggregates,
unless they contain some silicates, do not enhance the chemical
pozzolanic reaction of the block hardening, but they do add
strength to the block.
[0017] Other tests have indicated that blocks formed in the manner
of this invention can resist radiation, and a test has indicated
that when exposed to radiation, only about fifteen percent (15%),
at the maximum, of the radiation photons can penetrate through
these formed blocks. Hence, these types of blocks may have value as
an insulation at medical installations, where radiation is
frequently utilized.
[0018] This invention contemplates three aspects relating to its
concept, initially, the formulation and type of building block
constructed, and three methods or system by which the block may be
fabricated, in preparation for usage.
[0019] Essentially, the building block of this invention can be
fabricated of the open cavity type, but preferably, is constructed
into the configuration of a solid block, thereby providing it with
greater strength and less acceptable to fracture, because of the
solid integrated nature of its construction. Because of the type of
waste materials from which the block is fabricated as to be
sequentially described, and which may include some elements of wood
pulp, or the like, the block will accept and hold a nail, screw, or
the like, so that supplemental sheeting, whether exteriorly or
interiorly, can be applied and held directly to it, during
fabrication of a building. Furthermore, because of the inherent
nature of its ingredients, it can also be subject to cutting by a
power saw, or the like. In addition, the block of this invention,
because of its composition, has enhanced thermal resistant
characteristics, as can be understood. In addition, it can be
treated, with other ingredients, such as a borate, to render it
mold free and provide excellent termite resistance. It can function
as a sound insulation; even can be used as a party wall in
condominiums, hotels or near high-noise areas, like at airports, or
industrial parks, to provide that type of insulation; Rating
52.
[0020] Significantly, the block of this invention has high
strength, has a large load bearing capacity, due to its solid
configuration, and obviously provides safety during usage, can
lower energy bills, as previously alluded to, but at the same time,
is fabricated from generally waste ingredients, meaning that it
will be low cost in construction. The block is made generally of
about ninety nine percent (99%) waste materials, and therefore, is
earth-friendly, as can be understood.
[0021] In the preferred embodiment, the block may be constructed
having dimensions generally in the category of eight inches high,
eight inches deep, and sixteen inches wide
(8''.times.8''.times.16''). Obviously, other dimensions can be
readily applied during fabrication of the blocks of this
invention.
[0022] Generally, the formula for the compressed molded or low
pressure extruded or compressed blocks of this invention are
designed to provide maximum usage of waste material, such as fly
ash, as known in the art. For example, where it is desired to
fabricate a block having dimensions generally within the range of
eight inches by eight inches, and to any length
(8''.times.8''.times.any length), depending upon the mold, are the
cut-off point for the extruded type of block, it will include a
Class C Fly ash in a range of about fifty percent (50%) to ninety
percent (90%) by weight of the formulated block. Ground wood or
other small sized unpulverized aggregate as previously described,
may be applied in the vicinity of ten percent (10%) to thirty
percent (30%) by weight of the mixed formulation. Portland cement
may be added in a range of about ten to twenty percent (10% to
20%), for additional pozzolanic purposes because Portland cement
contains a significant higher percentage of calcium hydroxide.
Finally, optionally, boron, or zinc boride, may be added in the
range of one half percent to five percent (1/2% to -5%) by weight
of the mixed formulation, in order to furnish the mold protection,
and as a preventer of insect infestation, characteristics which are
desirable particularly since the formulation of this invention
includes ground wood ingredients, as previously explained. Class C
fly ash is readily available in abundance from the many coal fired
electric generating plants.
[0023] In addition, it needs to be emphasized that fly ash is
generated primarily through the processing of coal, and when coal
burns it provides an ash that generally produces a class C fly ash
and to some extent a class F fly ash.
[0024] In addition, other ingredients that may be used as aggregate
in lieu of ground wood. Effectively textile waste, rice hulls,
ground bamboo, straw, sea shells, sand, river sand, quarry sand,
and desert sand, all of which may be used, to add further strength
to the composition, from anywhere between thirteen percent (13%) to
twenty five percent (25%) by weight, thereby reducing the amount of
fly ash that may be necessary in the composition, or for reducing
the wood pulp ingredient, in order to provide enhanced strength to
the blocks, when formed, as can be understood. This is because
these types of aggregate matter, particularly textile waste,
bamboo, straw, or the like, all have a fibrous consistency which
has a tendency to bind the mixture together when moisture and a
plasticizer is added to the composition, before its molding into
the block form. Obviously, the greater the quantity of sand or
other glandular material that is added to the block, reducing the
wood pulp content, makes the block less isolative, and reduces the
ability of the finished block to accept and hold the nail and
screw, when applied during the fabrication of a building.
[0025] The system of fabricating the blocks of this invention
include the extruding method, which incorporates a cyclone wood
chip hopper, into which the chips may be included, and in which
hopper the fly ash from an outside silo may be delivered, to
provide for the proper mixing. A variable speed feeder may be used
to deliver the mixture to a pre-mixer, wherein treated water may be
added, and a displacement compressor provides the necessary
pressure on the mixture, as it is delivered to a variable speed
extruder, that may extrude a continuous block, to whatever cross
sectional dimensions desired, such as eight inches by eight inches
(8''.times.8''), but to any length before it may be cut off. Such
lengths may even be as great as four feet to sixteen feet long (4'
to 16'), for the extruded block, exiting from the operations of the
extruder. The block may then be conveyed to another location for
drying, curing, and storage, before it is shipped to the building
site, for usage.
[0026] The preparation of the compressed block may be achieved
through the usage of a hydraulic press, which exerts a ram force
upon the block ingredients, of the low pressures as described,
delivered to the site of pressing, where the blocks are instantly
formed under low pressure, into individual blocks, to dimensions as
desired, and then exit the compression chamber by way of a
conveyer, to a remote location for further drying and curing, or
for storage until usage. The type of modified hydraulic press, that
has been modified, and found useful for the purposes of building
the blocks of this invention, may be obtained from Encore Building
Solutions, Inc., of St. Louis, Mo.
[0027] Essentially, what is believed to occur when the composition
of Class C fly ash is mixed with treated water and waste material,
a pozzolanic reaction takes place, which essentially causes a new
matrix in the formulation, from its ingredients, and how the
ingredients are held together, into the formed block. The treated
water will include the plasticizer that acts as wetting agent to
accelerate the occurrence of the pozzolanic reaction. Furthermore,
other ingredients, in the category of an accelerator or retarder,
may be added to the composition, to either speed up the reaction
particularly during performance of the block forming process at
colder temperatures, or for slowing down the reaction during hot
temperatures. These ingredients will be subsequently described. All
of these identified materials, as explained, produce this
pozzolanic reaction that is a combination of minerals and mixtures
that mainly consist of fly ash, slag, and cilica fume. These
materials are all able to react with calcium hydroxide contained in
the Class C fly ash or Portland cement, and is said to have that
pozzolanic activity between the cellulose or granular material, the
fly ash, and the water, in addition to whatever Portland cement may
be added to the composition, for higher pozzolan levels. A
plasticizer, such as PLP accelerator Quantec PL-488" or a retarder
from W. R. Grace & Co., of Cambridge, Mass., or from General
Resource Tec., of Eagan, Minn., a plasticizer melchem accelerator,
Polychem Soper Set or retardant Polychem R or from Sika Corp., from
Marion, Ohio, a plasticizer Visco, accelerator rapid 1 retarder
plastment or from Master Builders, of Cleveland, Ohio composition.
That may be added in a range of 1/4 oz., to 30 oz., by hundred
weight of the fly ash in the mixed formulation. They function as a
wetting agent.
[0028] It is, therefore, the principal object of this invention is
to provide a unique building block that can be instantly fabricated
for immediate usage at low cost from generally waste ingredients
and materials.
[0029] Another object of this invention is to provide a molded,
even one constructed under low pressure, of a building block to a
variety of custom dimensions, at the selection of the builder, and
the owner.
[0030] Still another object of this invention is to provide a
medium weight fabricated building block.
[0031] Yet another object of this invention is to provide a
building block that has retention attributes, and can hold a nail,
or screw, upon application.
[0032] Still another object of this invention is to provide a
building block that may be fabricated having various grooves, in
order to allow the locating of reinforcing bars, utility conduits,
or the like.
[0033] Still another object of this invention is to provide a
building block having solid surface, and not necessarily made of
the cavity type prior art block, and therefore exhibits a much
larger load-bearing capacity than other type of fabricated
blocks.
[0034] Still another object of this invention is to provide a
treated building block that has high fire resistant rating.
[0035] Another object of this invention provides a building block
that will be mold resistant, insect and termite resistant since the
fly ash is a major ingredient, plus any organic inhibitors or
coatings provide high specification in resisting insect
infestation.
[0036] Yet another object of this invention is to provide a
building block that resists water penetration;
[0037] Still another object of this invention is to provide a
building block having a high wood content.
[0038] Another object is to provide a building block that
incorporates means to act as a fire retardant so as to minimize
damage when a fire occurs. Another object is to provide a building
block in which fire retardancy ingredients may be included so as to
minimize damage when a fire occurs. Generally, ASTM-E 119 requires
a four hour load bearing test with a five minute hose stream, to
sustain a wall structure when being sprayed for fire when
burning.
[0039] Another object of this invention is to provide a building
block that may be held together by thin set mastic, and does not
necessarily require the usage of any mortar as normally
accommodated and required between blocks in typical
applications.
[0040] Another object of this invention is to provide a building
block that exhibits thermal insulation value in the range of 20.5,
and higher ASTM-E 1363 Still another object of this invention
provides a building block that has excellent noise suppression
benefits. 52-rating ASTM-E 90.
[0041] Yet another object of this invention is to provide a
building block that eliminates the need for the stud-wall framing,
and insulation batting. This can be achieved, because it already
has good thermal insulation, and its wood content allows the
builders to nail or screw the exterior and interior sheeting and
other framing members, directly to the fabricated wall.
[0042] Another object of this invention, is to make a dry-stack
wall system where Earthblocks.TM., blocks with their tongue and
groove, top, bottom and both ends design allowing the blocks to be
screwed together, not martered.
[0043] Another object of this invention is to provide a building
block for use for fabricating walls, which in certain
jurisdictions, are already approved for general building usage.
[0044] A composition of the blocks formed in the manner as
described may be used to replace or eliminate stud walls, block
walls, adobe walls, and the like, in usage.
[0045] Another advantage of this particular invention is that walls
made from these blocks will result in far lower heating and cooling
bills.
[0046] Still another object of this invention is that blocks made
in accordance with this invention are formed of non-hazardous waste
materials, thereby protecting the environment, and reducing the
need for lumber, and other materials that are energy intensive and
expensive in their acquisition.
[0047] To reiterate, another primary object of this invention is to
provide a sustainable building product, being composed primarily of
waste materials. Hence, it provides a method by which waste
material may be disposed of and utilized, without filling the
landfills, with such waste material.
[0048] These and other objects may become more apparent to those
skilled in the art upon review of the summary of the invention as
provided herein, and upon undertaking a study of the description of
its preferred embodiment, in view of the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] In referring to the drawings, FIG. 1 provides an isometric
view of the fabricated building block of this invention;
[0050] FIG. 2 is a schematic view of one system for processing the
molding or compression, or extrusion, of the building blocks of
this invention;
[0051] FIG. 3 is a schematic view of the hydraulic press utilized
for the compression forming of the blocks as shown in FIG. 1 of
this invention;
[0052] FIG. 4 is an isometric view of one of the blocks, having
interengaging components, of this invention;
[0053] FIG. 5 is a top plan view of the block;
[0054] FIG. 6 is an end view of the block of FIG. 4; and
[0055] FIG. 7 is a schematic view of the preferred plant for
fabrication of the formed blocks from the mixture of ingredients as
defined for this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0056] In referring to the drawings, and in particular FIG. 1, is
an example of the way that the blocks can be fabricated by the
system of this invention as readily disclosed. The building block 1
will be of standard shape or appearance, but can be fabricated to
any size, but generally may be in the range of four inches high,
eight inches wide, and twelve inches in length
(4''.times.8''.times.12''). Obviously, other dimensions may be used
for the block of this invention, and depending upon which system is
used to fabricate the blocks, the dimensions are typically
91/2''.times.8''.times.171/2''. The extruded block, a block of any
length, even up to many feet in length, such as sixteen (16') as
previously stated, could be developed. Or, where the block is
molded by hydraulic pressure, it may have dimensions similar to
those as shown in FIG. 1. In addition, the block may be molded or
extruded having supplemental configurations, such as the upper and
lower grooves 2 and 3, in addition to the tongue and grooves 5-8,
as noted. The purpose of these grooves are to provide clearance,
either for the locating of reinforcing bars, or perhaps to locate
conduits, that may extend through the wall, and through which
electrical wires, or provide for heat conveyance, or other types of
utilities may be located.
[0057] As can be further seen in FIGS. 4-6, the preferred block of
this invention not only is fabricated from the mixture of
ingredients as summarized herein, but in addition, contains various
contours that facilitate their application together in forming a
wall, or the like. As can be seen, the block 4 is generally of the
same dimensions as the one previously described, but in this
example, included an integral extension 5, on the top, a recess 6
in the bottom, and an extension 7 and a recess 8, along either
ends, so that when the blocks are laid together, they may
interlock, to provide greater structural strength in holding the
wall together, and minimize the need for mortar or other mix. This
adds to the structural ability of the blocks to be integrated
together, in forming walls. Thus, both the vertical and horizontal
extensions, or tongue, and the recess or grooves, at both the top,
bottom and ends, provides an intermating of the blocks together, as
they are formed into a wall, and can be screwed together.
[0058] The formulation for the block of this invention can be seen
from the tables hereinafter provided. TABLE-US-00001 TABLE I
Molded, extruded, or compressed blocks all use the same mixtures.
Class C fly ash from about 50% to 90% Boron from about 1% to about
5% Ground wood from about 10% to about 50% or, other aggregates
such as sugar beet, waste lime, textile waste, sugar cane, bamboo,
rice hulls, and straw, in same proportions as above. Note, any
fibrous material will work as long as Class C fly ash is the main
ingredient. Treated water is applied to all these different
admixtures, from approximately 10% to approximately 30%, by
weight.
[0059] TABLE-US-00002 TABLE II Portland cement from about 5% to 30%
Class C fly ash from about 55% 50 80% Boron from about 1% to 5%
Ground wood from about 10% to 50% or other aggregates, such as
ground textile waste, sugar cane, bamboo, rice hulls, straw, or any
other strong fibrous material. Treated water is applied to these
different mixtures, from approximately 10% to approximately 30%, by
weight. This block has military applications
[0060] TABLE-US-00003 TABLE III Extruded industrial blocks 8''
.times. 8'' .times. any length Class C fly ash from 50% to about
65% Ground wood from 35% to 50% Portland cement from 1/2% to about
5% Boron from 1/2% to about 5% Treated Water sprayed up to from 20%
to 30%
[0061] TABLE-US-00004 TABLE IV Compressed industrial blocks 8''
.times. 8'' .times. any length Class C fly ash from 25% to 321/2%
Portland cement kiln dust 25% to about 321/2% Ground wood from 35%
to about 65% Portland cement from 1/2% to about 5% Boron from 1/2%
to about 5%, or
[0062] TABLE-US-00005 TABLE V Compressed industrial blocks 8''
.times. 8'' .times. any length Portland cement kiln dust from 50%
to about 65% Ground wood from 35% to about 65% Portland cement from
1/2% to about 5% Boron from 1/2% to about 5%
[0063] TABLE-US-00006 TABLE VI Vegetation waste blocks 8'' .times.
8'' .times. any length Sugar beet waste lime from 35% to about 65%
In addition to containing one or more of the ingredients Listed in
Tables I-V
[0064] TABLE-US-00007 TABLE VII Vegetation waste blocks 8'' .times.
8'' .times. any length Sea shell, sand, river sand, quarry sand, or
desert sand from 35% to about 65% In addition to containing one or
more of the ingredients Listed in Tables I-V
[0065] TABLE-US-00008 TABLE VIII Vegetation waste blocks 8''
.times. 8'' .times. any length Sugar beet waste lime from 35% to
about 65% In addition to containing one or more of the ingredients
Listed in Tables I-V
[0066] It should be recognized herein that the treated water in the
amount of ten percent (10%) to approximately thirty percent (30%0
is applied to the mixture in forming the various blocks, as
identified in the Tables herein, will include an additional
ingredient of a plasticizer, such as that described in this
application as available under the brand name PLP, from W. R. Grace
& Co., in order to act as a wetting agent that accelerates the
full wetting of the mixture materials, whether they be the fibrous
material or the aggregates, to achieve complete moisturization of
the ingredients before they are molded into the block form. It is
also at this time that one of the accelerators or retarders may be
included, in order to facilitate the mixing process, when the
ambient temperatures may be in the significantly cold, or heat
ranges, wherever this process is utilized.
[0067] As can be seen from FIG. 7, the system for extruding,
molding, or, compressing the industrial building blocks of this
invention is readily disclosed. As noted, the ingredients for the
block are processed by the system, as disclosed. For example,
pre-ground wood chips, as at 40, are delivered via a variable speed
walking floor 41, to a conveyor 42, to a hammer mill 43, to provide
a secondary grinding of the chips. The ground and pulverized wood
will be conveyed to a roto-paddle blower 44, and delivered by
conduit tubing 45, for emitting into the upper end of a cyclone
wood chip hopper 46, as can be noted. Support structure, as at 47,
provides the bracing necessary for structurally holding the system
in place. From the cyclone wood chip hopper, the ground wood, which
may include wood chips, wood dust, paper pulp, ground up cardboard,
or any other of the pulp ingredients, are delivered to a variable
speed rotary-air lock, as at 48. At this juncture, the proper
amount of the wood ingredient is delivered to a vibrating
classifier 59, where the dust and extra fines are removed and sent
to the fine hopper, 50 by augar 51, as noted. At this point, into
the pre-mixer 52, fly ash from an outside silo source 53 is
delivered by way of a variable speed auger 54, to the pre-mixer.
The fly ash may be generated and deposited into the silo from any
coal fired power plant.
[0068] In addition to the delivery of the wood chip component, and
the fly ash from external sources, water, by way of the positive
displacement water pump, 53a, is also metered into the feed water
line after the pump via the positive displacement additive pumps,
57 in an amount to provide it with the proper degree of texture
that renders the mixture more pliable, and capable of being either
molded, extruded, or compressed, as can be understood. The amount
of the ingredients added, including the water, can be determined
from the formulations as previously set forth.
[0069] From the pre-mixture, a variable speed mixer further mixes
up the ingredients, as at 52, and delivers it to a variable speed
extruder, molder, or hydraulic press, that moves the formulated
material in continuous lengths, as can be seen by the block exiting
from the extruder die, as at 58. At this juncture, the blocks may
be cut to the desired lengths, which may be anywhere from inches,
up to four feet through sixteen feet in length, as noted. At this
point the cut blocks will then be conveyed upon the conveyor 56, to
a location for drying, curing, storage, or even for use for
installation at a building site.
[0070] As an example of usage of the molding, compression,
extruding process, utilizing the system. As can be seen from FIG.
2, the batch system for extruding the industrial building blocks of
this invention is readily disclosed. As noted, the ingredients for
the block are processed by the system, as disclosed. For example,
pre-ground wood chips, as at 10, are delivered by conveyor 11, to a
hammer mill 12, to provide a secondary grinding or pulverizing of
the chips. The ground and pulverized wood will be conveyed by a
blower 13, to a roto-paddle blower 14, and delivered by conduit
tubing 15, for emitting into the upper end of a cyclone wood chip
hopper 16, as can be noted. Support structure, as at 17, provides
the bracing necessary for structurally holding the system in place.
From the cyclone wood chip hopper, the ground pulp, which may
include wood chips, wood dust, paper pulp, ground up cardboard, or
any other of the pulp ingredients, are delivered to a variable
speed roto-feeder, as at 18. At this juncture, the proper amount of
the wood ingredient is delivered to a pre-mixer 19, as noted. At
this point, and into the pre-mixer, fly ash from an outside silo
source 20 is delivered by way of a positive displacement compressor
21, through a conduit 22, to the pre-mixer. The fly ash may be
generated and deposited into the silo from any of the variety of
sources for this type of ingredient. For example, it may be the fly
ash from a cement plant. Or, it may be the fly ash generated from
many of the other installations that generate class C fly ash
[0071] In addition to the delivery of the wood chip component, and
the fly ash from external sources, water, by way of the conduit 23,
is also metered into the pre-mixer, in an amount to provide it with
some degree of texture that renders the mixture more pliable, and
capable of being either extruded, or compressed, as can be
understood. The amount of the ingredients added, including the
water, can be determined from the formulations as previously set
forth.
[0072] From the pre-mixture, a variable speed mixer further mixes
up the ingredients, as at 24, and delivers it to a variable speed
extruder, that extrudes the formulated material in continuous
lengths, as can be seen by the block exiting from the extruder dye,
as at 25. At this juncture, the blocks may be cut to the desired
lengths, which may be anywhere from inches, up to four feet through
sixteen feet in length, as noted. At this point the cut blocks will
then be conveyed upon the conveyor 26, to a location of drying,
curing, storage, or even for use for installation at a building
site.
[0073] The percentages of the ingredients for the block formulation
when the sugar beet waste lime is applied may be determined from
the following table.
[0074] In the formation of the blocks from the hydraulic or other
pressure compressed blocks, the material will be formed similar in
the manner as the pre-mix for the extruding, or molding process,
including up to the delivery of the Class C fly ash and wood, etc,
to the plant, for mixing, as previously explained. The material
from the mixer, in the extruding process of FIG. 2, will be left
dry, and bagged, for delivery to the feed hopper, of the Encore
Building Solutions, Inc., St. Louis, Mo. Another extruding process
for compressing blocks, at low pressure, into the building block
form may be obtained from Encore Building Solutions, Inc., of St.
Louis, Mo.
[0075] Generally, the same formula is used as in the extruding
process, but in the high pressure press, other blends will also
work because of the pressure involved, up to three thousand pounds
(200-600 lbs.) per square inch, which is further effective in
forming the desire block.
[0076] The pre-mix is added to a feed hopper, with a blender, built
into it. A liquid pump delivers water by way of a twelve volt
marine type pump. This makes the press totally self contained,
portable, and with the hydraulic press being provided directly upon
the trailer frame, when constructed. Once the hydraulic engine is
turned on, the pre-mix is poured into the feed hopper, delivered to
the blender; some moisture is added, generally in the range of
enough water to make a substantially viscous pre-mix. The press is
then applied, after a batch of the materials provided into the
mold, at the compression chamber, for immediately forming a block.
A spray system may be used for adding the treated water at the
blender/mixer, and the water tank assembly holds approximately one
hundred gallons of water. The compression chamber, at the mold, may
include a weighing device, to ensure that the proper amount of
materials is added into the mold, before compression is initiated.
The mold may also be constructed in a manner to provide the shape
the block is desired, as for example, the mold may contain the semi
circular protrusions, in order to form the grooves 2 and 3, within
the finished block, when compressed. Also, the tongue and groove
arrangements, 5-8, can also be formed in a similar manner.
[0077] Blocks formed in the manner as described exhibit very little
shrinkage once formed and used in wall formation. Furthermore, when
subjected to a freeze-thaw test, ASTM C-679 ASTM C-1262, very
little breakage or shattering of the blocks have been experienced.
It has been found that the blocks, when formed into a wall, provide
enhanced retarding against sound transmission through the wall when
employed. Thus, there is a noise reduction. Apparently the blocks
have a tendency to absorb sound.
[0078] Variations or modifications to the subject matter of this
invention may occur to those skilled in the art upon reviewing the
disclosure as provided herein. Such variations, if within the
spirit of this development, are intended to be encompassed within
the scope of the invention as described herein. The description of
the preferred embodiment, and as shown in the drawings and
schematics, is set forth for illustrative purposes only.
* * * * *