Method for forming lightweight concrete block
AssigneeAdvanced Building Systems, Inc.
InventorDaniel M. Jensen
Life of this patent
Estimating the term…
Abstract
A method and apparatus for efficiently forming individual building units is provided, generally includes providing a plurality of molds, each capable of simultaneously forming a plurality of building units. Batches of cementitious slurry are individually mixed in order to control the density of each building unit formed. The ingredients are individually measured and combined into the mixing device. The cementitious slurry is then conveyed or transported and poured into one of the molds. The method provides the ability to control the amount of cementitious slurry in each batch in order to control to the extent possible the quantity of cementitious slurry poured into each mold and the ability to precisely control the dimensions of each building unit produced.
Claims34
A method of forming a lightweight concrete building unit, comprising:
- providing a first mold having a plurality of side walls defining at least one mold cavity;
- forming a batch of cementitious slurry by mixing at least one dry cementitious ingredient, water and a temperature sensitive foaming agent for producing air cells in the cementitious slurry, wherein the foaming agent has a critical temperature at which the foaming agent destabilizes, wherein the cementitious slurry is formed at a temperature below the critical temperature;
- heating the sidewalls of the first mold to at least the critical temperature;
- dispensing said batch of cementitious slurry into said at least one mold cavity;
- and
- compressing said cementitious slurry from a first position to a substantially precise second position within said first mold,
- wherein the heat from the mold enables the slurry to form into a building unit and the heat causes air cells in the building unit to collapse to yield a closed cell surface and a dense outer layer around a less dense, lightweight inner core,
- wherein compressing said cementitious slurry assists in further collapsing air cells to increase the density of the outer layer.
A method of forming a lightweight concrete building unit, comprising:
- providing a first mold having a plurality of side walls defining at least one mold cavity;
- forming a batch of cementitious slurry by mixing a plurality of dry cementitious ingredients, and a temperature sensitive foaming agent for producing air cells in the cementitious slurry, wherein the foaming agent has a critical temperature at which the foaming agent destabilizes, and heated water having a temperature below the critical temperature;
- heating the sidewalls of the first mold to at least the critical temperature;
- dispensing said batch of cementitious slurry into said at least one mold cavity;
- and
- compressing said cementitious slurry from a first position to a relatively precise second position within said first mold,
- wherein the heat from the mold enables the slurry to form into a building unit and the heat causes air cells in the building unit to collapse to yield a closed cell surface and a dense outer layer around a less dense, lightweight inner core,
- wherein compressing said cementitious slurry assists in further collapsing air cells to increase the density of the outer layer.
A method of forming a lightweight concrete building unit, comprising:
- providing a first mold having a plurality of side walls defining at least one mold cavity;
- forming a batch of cementitious slurry by mixing at least one dry cementitious ingredient, water and a temperature sensitive foaming agent for producing air cells in the cementitious slurry, wherein the foaming agent has a critical temperature at which the foaming agent destabilizes, wherein the cementitious slurry is formed at a temperature below the critical temperature;
- heating the sidewalls of the first mold to at least the critical temperature;
- dispensing said batch of cementitious slurry into said at least one mold cavity;
- and
- compressing said cementitious slurry from a first position to a substantially precise second position within said first mold,
- wherein the heat from the mold enables the slurry to form into a building unit and the heat causes air cells in the building unit to collapse to yield a closed cell surface and a dense outer layer around a less dense, lightweight inner core,
- wherein compressing said cementitious slurry assists in further collapsing air cells to increase the density of the outer layer
- wherein the at least one dry ingredient and the foaming agent are selected and the temperatures of the cementitious slurry and the mold are selected to enable the building unit to cure to a handleable state in no more than approximately 10 minutes.
Dependencies are inferred from the claim text.