Building block and system for manufacture
AssigneeEncore Building Solutions, Inc
InventorRobert F. Sinclair
Life of this patent
Estimating the term…
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. A plasticizer, wetting agent and surfactant solution may be added to the composition. 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.
Claims14
A building block capable of accepting a wood screw or nail in usage, said block being uniformly 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 being entirely 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 containing calcium oxide 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 form selected from ground wood, textile fiber, ground bamboo, rice hulls, and ground wood or chips, having a fibrous length of approximately ⅛ inch to 11/16 inch in length, and being approximately 1/16 inch in diameter or width, and mixed in the formulation between about ten percent (10%) to fifty percent (65%) by weight of the mixed formulation,
- ground dehydrated gypsum added to the composition in an amount of between about 3% to 5% by weight of mixture,
- a surfactant solution functioning as a wetting agent and maintaining flow-ability to the mixture when water is added to the mixture up to approximately 2% by weight of the 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 as the pozzolanic reaction commences to form the mixture into the block form.
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 selected from ground wood, textile fiber, ground bamboo, rice hulls, and wood chips, all in the category of fibers having dimension of approximately ⅛ inch to 11/16 of an inch in length, and having a diameter or width of approximately 1/16 of an inch, 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.
The process for manufacturing by pressure molding building blocks of the type capable of accepting a wood screw or nail in usage, initially entailing the delivery of wood chips through a hammer mill, to provide for a secondary grinding of the chips into fibrous form, delivering the ground chips to a cyclone wood chip hopper, screening from the cyclone wood hopper the ground wood including wood chips having a fibrous length of approximately ⅛ inch to 11/16 of an inch in length, and having a diameter or width of approximately 1/16 in inch as screened from the wood delivered from the chip hopper, further delivering the wood ingredient to a vibrating classifier where dust and extra fines are removed, adding the fibrous wood into a premixer and adding fly ash from a separate source into the premixer, adding water in an amount of approximately 10% to about 20% by weight into the premixer, while also adding a plasticizer in the form of a wetting agent that accelerates the full wetting of the mixed materials, adding the wetted mixed material into a press, and subjecting the premixed material to pressure in the range of about 200 psi to 600 psi just after the pozzolanic reaction commences to form the mixture into the block form when full pressure has been applied.
Dependencies are inferred from the claim text.