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  Building block and system for manufactureUSPTO Application #: 20070011973Title: Building block and system for manufacture Abstract: A compressed building block formed of a pre-mix of fly ash, either of the Class C type, or provided from sugar beet waste lime, are combined with either ground or pulverized wood and/or chips, or with fine sand, having a small amount of Portland cement added thereto, moisturized, and then either extruded or compressed in a press into the configuration of a block. A fire 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 hydraulic or other press and pressed into the configuration of the desired block, needed for the construction. (end of abstract)
Agent: Paul M. Denk - St. Louis, MO, US Inventors: Robert F. Sinclair, Colvin J. Schwartz, Gail B. Schwartz USPTO Applicaton #: 20070011973 - Class: 052503000 (USPTO) The Patent Description & Claims data below is from USPTO Patent Application 20070011973. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a continuation 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 com-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, in the category of wood chips, sawdust, fly ash, and other types of ash products, even that which may be esoterically created upon the burn-off of beets, plants, and leafage, which normally is discarded. The resulting fly ash from the burning of this type of waste material has been found to be effective has an ingredient to the formation of building blocks for industrial usage. [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. 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. [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 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 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] This invention contemplates three aspects relating to its concept, initially, the formulation and type of building block constructed, and two methods or system by which the block may be fabricated, in preparation for usage. [0012] 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 has to be sub 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, 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 composition, 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 fire resistant and provide excellent termite resistance. It can function as a sound insulation; even can be used as a party wall in or near high-noise areas, like at airports, or industrial parks, to provide that type of insulation. [0013] 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. [0014] 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. [0015] Generally, the formula 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. 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 sixty five percent (65%) by weight of the formulated block. Ground wood, such as sawdust, or wood chips, may be applied in the vicinity of thirty five percent (35%) to fifty percent (50%) by weight of the mixed formulation. Portland cement may be added in a range of about one to three percent (1/2% to 5%), for adhesion purposes. Finally, optionally, boron, or a 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 fire 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. [0016] In addition, fly ash generated from other waste materials, such as previously alluded to, the waste vegetation matter left over upon the harvesting of plants such as the sugar beet, and many of the other vegetation grown, provides a fly ash, upon burning, that is found to be just as effective for usage in the formulation of this invention. [0017] In addition, other ingredients that may be used effectively include 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 thirty five percent (35%) to sixty five percent (65%) 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. 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. [0018] 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 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. [0019] The preparation of the compressed block may be achieved through the usage of a hydraulic compressor, which exerts a ram force upon the block ingredients, delivered to the site of compression, where the blocks are instantly formed under extensive 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 compressor, that has been modified, and found usage for the purposes of building the blocks of this invention, may be obtained form Vermeer manufacturing Company, of Pella, Iowa, as an example, under model No. HBP520, or a related type of hydraulic or other pressure inducing compressor. [0020] It is, therefore, the principle 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. [0021] Another object of this invention is to provide a molded, even one constructed under pressure, of a building block to a variety of custom dimensions, at the selection of the builder, and the owner. Continue reading... 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