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Building block and system for manufactureBuilding block and system for manufacture description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060037271, Building block and system for manufacture. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATION [0001] The subject matter of this continuation-in-part patent application is related to the subject matter of the continuation-in-part application having Ser. No. 10/815,533, which was filed on Apr. 1, 2004, which claims priority to the non-provisional patent application Ser. No. 10/411,551 which has a filing date of Apr. 10, 2003, which claims priority to the provisional patent application having Ser. No. 60/371,441, which was filed on Apr. 11, 2002, and is owned by a common assignee. 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 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 industrial type of buildings, and even some 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 concrete, can be formed in 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 construction. 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 does not rely on cement as it utilizes extensively what are currently considered as wood substitutes: wood chips, sawdust, textile waste, and fly ash, among other things. [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 mixture 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 emulsion, even one which can be mixed with water to form a liquid. Preferably the adhesive binder is polyvinyl acetate, which can be added to the mixture as an emulsion. The mixture 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 mixture. [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: construction. [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 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 cementous 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 Mixtures, 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 Mixture 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, and lastly the patent to Nutt, U.S. Pat. No. 3,753,749, shows other Concrete Mixtures. SUMMARY OF THE INVENTION [0010] This invention relates primarily to the construction of a unique building block, one fabricated totally from waste materials and without a binding agent, and a number of systems by which the block may be fabricated and molded, into a high strength finished product. This invention contemplates three aspects relating to its concept: initially, the formulation and type of building block constructed, and two methods or systems by which the block may be fabricated, in preparation for usage. [0011] 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 susceptible to fracture, because of the solid integrated nature of its construction. Because of the type of waste materials from which the block is fabricated, including wood pulp, or the like, the block will accept and hold a nail, screw, or the like, so that supplemental sheeting, rather 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 mixture, has enhanced thermal resistant characteristics, as can be understood. In addition, it can be treated, with other ingredients, such as a boride, to render it termite and mold resistant. It can function as a sound insulation; even can be used as a sound wall in or near high-noise areas, like at airports and industrial parks, and as dividing walls for adjacent condominiums and apartments, to provide that type of insulation. [0012] Significantly, the block of this invention has high strength and a large load bearing capacity due to its solid configuration, and obviously provides safety during usage, lowers energy bills, and as previously alluded to, 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 a "green" building material, as can be understood. [0013] In the preferred embodiment, the block may be constructed having dimensions generally in the category of nine and 1/2 inches high, eight inches deep, and seventeen and 1/2 inches wide (9.5''.times.8''.times.17'- ') including the tongue and groove jointed edges. Obviously, other dimensions can be readily applied during fabrication of the blocks of this invention. [0014] Generally, the formulae for the compressed or extruded blocks of this invention are designed to provide maximum usage of waste material, such as fly ash, as known in the art, without cement or other binder. For example, where it is desired to fabricate a block having dimensions generally within the range of nine and 1/2 inches by eight inches, and to any length (9.5''.times.8''.times.any length), depending upon the mold, 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. Wood pieces or cellulose materials, such as chips or chunks, may be applied in the vicinity of ten percent (10%) to fifty percent (50%) by weight of the mixed formulation. Optionally, boron, or a boride, may be added in the range of one half percent to five percent (1/2% to 5%), in order to furnish the mold retardency 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. In an alternate embodiment for the military, Portland cement may be added in a range of about two to twenty percent (2% to 20%), for ballistic or hardening purposes. [0015] Other ingredients that may be used effectively in addition to fly ash include wood, wood ash, sugar beat wast lime, rice straw, wheat straw, cotton stalks, sugar cane, bamboo, sea shells, sand, river sand, quarry sand, and desert sand, all of which may be used as wood substitutes, to add further strength to the mixture, from between ten percent (10%) to thirty percent (30%) by weight, thereby reducing the amount of fly ash that may be necessary in the mixture, or for reducing the wood chip ingredient, in order to provide enhanced strength to the blocks, when formed, as can be understood. Obviously, the greater the quantity of sand or other granular material that is added to the block, reduces the wood pulp content, makes the block less isolative, and reduces the ability of the finished block to accept and hold a nail and a screw, when applied during the construction of a building. [0016] Two other essential ingredients for the mixture for forming the building block of this invention includes the addition of a Plasticizer agent to the composition, during its mixing, for the purpose of providing a dispersion of the mixed components within the ingredients, including water, that results in a more thorough mix of the ingredients, and allows for their better flow ability, during the deposit of the formal into the forms. In addition, an accelerator is useful for re-acting the fine particles of the mixture with all of the other ingredients, during mixing, so as to more quickly and better form the slurry for addition to the forms, during molding of the blocks. [0017] The system of manufacturing the blocks of this invention includes the extruding method, which incorporates a cyclone wood chip hopper, into which the chips may be placed, 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 desired cross sectional dimensions, such as nine and 1/2 inches by eight inches (9.5''.times.8''), but to any length. Such lengths may even be as great as four feet to sixteen feet long (4' to 16'), for the extruded block, exiting from 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. [0018] 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, delivered to the site of compression, where the blocks are instantly formed under modest 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 found usage for the purposes of building the blocks of this invention, may be obtained from Vermeer Manufacturing Company, of Pella, Iowa, or a related type of hydraulic or other press. [0019] It is, therefore, the principle object of this invention is to provide a unique building block that can be instantly manufactured for low cost from generally waste ingredients and materials. [0020] Another object of this invention is to provide a molded, even one constructed under pressure, building block to a variety of dimensions, at the selection of the builder, and the owner. [0021] 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. Continue reading about Building block and system for manufacture... Full patent description for Building block and system for manufacture Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Building block and system for manufacture patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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