Note: Descriptions are shown in the official language in which they were submitted.
CA 02831629 2013-11-01
Description
Technical Field
This invention is a kind of building block that is made through crushing,
mixing and repressing
one or several of wheat straw, corn stalks, corn cobs, soybean straw, rice
straw, reed rods, wood
chips, wood, twigs, sunflower stalks, hay, bran, wheat bran, waste and other
organic materials
(hereinafter referred to as: organic building block), belonging to the field
of building materials.
Invention Background
Wood building house is a characteristic of North America and enjoys a great
popularity. However,
it consumes large quantities of wood, causing a great destruction on shrinking
forests. Timber
prices are also rising, housing construction costs therefore improves. On the
other hand, a large
number of wheat straw, corn stalks, corn cobs, soybean straw, rice straw, reed
rods, wood chips,
wood, twigs, sunflower stalks, hay, chaff, wheat bran, waste and other organic
materials
produced by the largest global producers of wheat, corn, soybeans and other
crops in Canada and
United States can not be fully utilized while treated as waste. For many
years, millions of people
or companies in the world have been studying how to produce building materials
by making full
use of organic materials such as corn stalk and wheat straw, which has also
made a lot of
achievements like the production of furniture using corn stalks and wheat
straw. Nevertheless,
since manufacturers do not notice that organic materials do not have the
characteristics of wood
and blindly pursue wood-alternative products, resulting in a quite high
production cost and the
limited sales market. What's more, the practice of pursuing wood-alternative
products only
makes it possible to use a few organic materials such as wheat straw and corn
stalks, leaving
large amounts of other organic material having not been large-scale and fully
applied. In addition,
to solidify plates made of wheat straw and corn stalk that lack wood
toughness, a large number
of chemical adhesives has to be used, not achieving the objective of fully
environmental
protection.
During housing construction in North America, cotton insulation made of glass,
rock or silica
CA 02831629 2013-11-01
powder clay clinker, alumina powder, chromium sand and other materials has
been used in many
houses to fill the gap between the outer wall and inner wall for insulation
and soundproofing.
Although it has the advantage of being relatively light, but its insulation
and soundproofmg
effects is far inferior to those of the more and more expensive wood and
masonry. However, if
the houses only use solid wood or masonry, building costs would be soared, so
most of the
houses do not use a lot of solid wood or increase the use of masonry and the
situation of
extensively using cotton insulation will continue. The point is now there is a
serious problem of
environmental pollution by the extensive use of cotton insulation. That is,
even though cotton
insulation products are not harmful to health, what cotton insulation
manufacturers have ignored
is the cotton insulation rubbish during housing demolition and renovation. It
will pollute the
environment for many years, especially for the hazards to human health and
soil and water
pollution by the flowing insulation cotton fiber in the air. Furthermore, its
production process
also produces severe dust pollution. Last but not least, cotton insulation
prices are also increasing
because of resource constraints and the high cost of energy.
This patent will just resolve: 1, fully utilize wheat straw, corn stalks, corn
cobs, soybean straw,
rice straw, reed rods, wood chips, wood, twigs, sunflower stalks, hay, bran,
wheat bran, waste
and other organic materials as excellent and inexpensive construction
materials; 2, avoid
problems of large quantities of chemical binder admixture with the current use
of the existing
wheat straw, corn stalks, corn cobs, soybean straw, rice straw, reed stick,
wood chips, wood,
twigs, sunflower stalks, hay, bran, bran, waste and other organic materials
during the building
materials production, completely chemical free with cheap construction
materials; 3, replace
most of the currently used insulation and soundproofing materials such as
cotton which will
produce serious pollutions.
Summary of the Invention
This invention is a kind of organic building material, a kind of building
block that is made of
through crushing, mixing and repressing one or several of wheat straw, corn
stalks, corn cobs,
soybean straw, rice straw, reed rods, wood chips, wood, twigs, sunflower
stalks, hay, bran, wheat
bran, waste and other organic materials. In the use of these organic
materials, it does not
necessarily pursue the production of panels with high strength and toughness
that is similar to
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CA 02831629 2013-11-01
wood. Instead it avoids the shortcomings of such lack of wood characteristics
and relative
looseness of wheat straw, corn stalks, corn cobs, soybean straw, rice straw,
reed rods, wood chips,
wood, twigs, sunflower stalks, hay, bran, wheat bran, wood waste and other
organic materials by
producing building blocks with similar size of building bricks. In this way it
also makes full use
of a large number of organic materials that are treated as waste and produces
excellent
inexpensive materials that are widely used and pollution free.
1. According to the claims, it is a kind of building block that is made
through crushing, mixing
and repressing one or several of wheat straw, corn stalks, corn cobs, soybean
straw, rice straw,
reed rods, wood chips, wood, twigs, sunflower stalks, hay, bran, wheat bran,
waste and other
organic materials, most of which are currently treated as waste.
2. According to the claims, its design is: these organic materials are
collected up to remove
sludge and cut rhizomes that can not be used for building blocks (but they can
be made into
fuel when crushed and compressed - a separate application patent), chopped or
crushed into
0.5-2 mm debris, blended with a certain percentage binder and lime powder,
added with a
certain percentage of water, blended in blender and pressed into building
blocks in various
shapes through high pressure molding after heating. The basic shape please see
the Figure 1
3. According to the claims, the wheat straw, corn stalks, corn cobs, soybean
straw, rice straw,
reed rods, wood chips, wood, twigs, sunflower stalks, hay, bran, wheat bran,
waste and other
organic materials are crushed into 0.5 -2 mm detritus. Its purpose is to fully
mix the binder,
water and lime powder together and get them prepared for pressing. If not, it
would be the
other way around, thus affecting the effect of compression molding.
4. According to the claims, the approximate stirring ratio of binder, water,
lime and detritus of
crushed wheat straw, corn stalks, corn cobs, soybean straw, rice straw, reed
rods, wood chips,
wood, twigs, sunflower stalks, hay, bran, wheat bran, waste and other organic
materials is:
80-85% organic materials, 2-5% binder, 10-18% water and 3-5% lime powder. It
can also be
adjusted according to the organic material composition. If there is more
water, mixing and
molding as well as press would be relatively easy, but it takes a long time to
dry. Therefore,
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the proportion of water can be adjusted according to the material and the
circumstances.
Then the prepared organic material, binder, water and lime according to the
proportion can
be put into the mixer and thoroughly mixed.
5. According to the claims, the binder component of this patent is one or more
of non-toxic
resins, waste paper pulp and glutinous rice paste. Non-toxic resins are
expensive while waste
paper pulp and glutinous rice paste are very cheap binders with high
qualities, especially that
the later one has been used by the Chinese people to make adhesive from
thousands of years
ago. The strong walls of the Forbidden City in Beijing, China have been
standing still for
centuries, and they are bonded with glutinous rice paste, which is completely
natural without
any artificial chemical compositions at low prices.
6. According to the claims, the organic materials, binder, water and lime are
heated to 130-160
C while being stirred. The reason to be heated are: 1, stirred organic
materials, binder,
water and lime can go to further integration when heated and the gaps and
bubbles in stirred
organic materials can be squeezed out as much as possible; 2, bugs and their
eggs possibly in
stirred organic materials can be killed.
7. According to the claims, the proportion of lime added during stirring is 3-
5%. This addition
is to prevent insects from growing in blocks made of organic materials. What's
more, lime
can also function as binder.
8. According to the claims, stirred organic materials take high-pressure
compression molding
after heating. The high pressure is around 315KGF/CM2 (according to material
properties)
and the organic materials will be pressed into the volume that accounts
fifteenth to thirtieth
of its original one. Blocks of organic materials through high-pressure
compression are sturdy
enough to be used as building materials.
9. According to the claims, stirred organic materials go through hollow
molding (Figure 2) at
high temperature and pressure to reduce weight and improving insulation.
10. According to the claims, stirred organic materials are also pressed into
bilateral occlusal
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CA 02831629 2013-11-01
shape (Figure 3) through compression molding at high temperature to increase
the bonding
between the blocks.
11. According to the claims, after stirred organic material going through
compression molding at
high temperature, the building blocks can be sandwiched in paper or fabric,
bamboo, Barbed
wire, etc. of toughness to enhance their toughness and sturdiness.
12. According to the claims, after stirred organic material going through
compression molding at
high temperature, pressed blocks are designed piping and wire arrangement
dedicated to
facilitate the arrangement.
13. According to the claims, after stirred organic material going through
compression molding at
high temperature, pressed blocks are designed with fishtail slots and fish
tail wedges, which
can be used for block connection in building houses (Figure 4-1) and to avoid
using nails or
chemical adhesives (Figure 4-2).
