US1796559A

US1796559A - of cincinnati

Info

Publication number: US1796559A
Authority: US
Publication date: 1931-03-17
Anticipated expiration: 1948-03-17

Description

Patented Mar. 17,1931

UNITED STATES PATENT OFFICE HOW'ARD C. BYLAND AND FRANK L. ORMESHER, OF CINCINNATI, OHIO. ASSIGNORS TO CEMROC, INC, OF CINCINNATI, OHIO, A CORPORATION OF OHIO PROCESS OF MANUFACTURING BUILDING UNITS No Drawing.

Our invention relates to a process of manufacturing a building unit.

It is the object of our invention to provide a process of forming a plastic building unit 5 that will immediately set in its proper form, that will have high resistance to moisture absorption and great strength, and can be air dried within the minimum time so that it may be quickly used after having been formed.

Particularly,it is the object of our invention to be able to employ concrete, or cement combined with various kinds and types of aggregates, by this process of manufacturing, by forming the material out of concrete, or out of a combination of cement and other ingredients, under pressure, and at the same time provide a building unit that will have high resistance to moisture and adequate strength, which have been qualities not heretofore existent in molded concrete products, or those in which cement has been combined with Various other ingredients.

The invention consists in subjecting a 5 mixture of concrete, or a mixture of cement and other ingredients to great pressure in a small area, by first pounding or tamping the material, or by first pounding or tamping the material, and then subjecting it to pressure,

30 or by pressure alone, therebythoroughly dispensing it in a mold and then subsequently condensing it *by either pounding and tamping, pounding and tamping and then pressure, or by pressure alone.

For instance, it has been found that by use of a tamper of 700 pounds in weight dropping a distance of 18", that a body of concrete or combination of cement and various kinds and types of ingredients having approximately the square surface of an ordinary brick, which is approximately 4 x 8", or a square surface of 32", will be compressed approximately and brought to the usual brick thickness, which isapproximately 2 4". A pounding, tamping, or striking pressure of approximately 1000 pounds distributed over approximately a dozen brick units will be found to be satisfactory. The square dimensions ofeach of Application filed. September 15, 1928. Serial No. 306,286.

tamping, or striking blow subsequent pressure which may vary any amount but which is preferred to have approximately a 75 ton pressure, although as low as 8 or 10 tons have been found to be satisfactory for some types of unit. The application of the additional pressure as indicated up to as high as 7 5 tons will cause a reduction in the thickness of the unit of about five-eighths of an inch.

It has been found, in the operation of machines practicing this process, the variations in the mixture of the aggregates forming the concrete, or the aggregates combined with cement and other ingredients, will be accommodated so that auniform product will be assured, which is a condition very difficult to otherwise control.

Thus, the thickness of the unit before applying the pounding, tamping, or striking, is usually two and three-fourths of an inch in depth in the mold. But if pressure is to be subsequently added after the tamping operation, or if pressure alone isto be applied, the unit should be approximately two and sev en-eights of an inch in depth in the mold. The resulting applicationof the forcesindicated above will bring the product to a thickness of approximately two andone-fourth of an inch. It is preferred to usethe combination of the tamper and then the pressure.

In addition to the foregoing, in order to improve the rapidity with which the product sets, and the water proofing qualities of the product, we add into the aggregate composing the concrete, or combined with cement and other ingredients, ammonium stearate and calcium chloride and other ingredients,

or stearic acid and calcium chloride and other ingredients respectively for the purpose of water proofing and acceleration of the setting.

Stearic acid further acts as a lubricant and facilitates the distribution of the material in the mold under any type of pressure, and its extraction when stripped from the mold.

The exact proportions of such materials are more fully set forth in applications Serial Nos. 272,853, 272,854, 293,798, and 293,791 now pending in the United States Patent Ofiice.

Vi e further find that it is desirable to add coloring material, such as mineral oxide, and that, when the method of manufacturing these building units is followed, the addition of mineral oxide does not weaken or change the absorption qualities of the resulting product. Nor will the mineral oxide fade because of the acceleration of the setting of the material which is facilitated by its high pressure, homogeneous character, and rapid setting due to acceleration.

This is also becaus the combination of stearic acid, calcium chloride, and other ingredients immediately and properly set up the cement so that it will have no reaction on the mineral oxide. The combination of stearic acid, calcium chloride, and other ingredients also hermetically seals the voids in the product, thus preventing penetration by moisture, air and chemicals which prevents alteration of the color of the finished product. By reason of the fact that the combination of stcaric acid, calcium chloride and other ingredients lubricates the material, it makes a denser unit, thereby causing a mechanical sealing of the voids. lVhile at the same time it generates heat in the concrete, or cement combined with various kinds and types of aggregates and other ingredients, and thus keeps it at a uniform temperature so that the cement will have the proper colloidal action.

lVhile varying types of aggregate for the concrete may be employed, it is preferred to employ a typical combination of six feet of sand comprised of three feet of clean fine sharp sand and three feet of coarse sand or gravel for every 94 pounds of cement. Where no coloring is used this aggregate is mixed thoroughly dry for approximately two minutes. It is then dampened by a line spray di rected onto the materials at an angle of approximately 45 degrees, while the concrete mixer is running thus agitating the material. From 4 to 8 gallons of water is added in this manner, the amount of water varying accord ing to the condition of the aggregates at the time they are placed into the concrete mixer. lVhile the lto 8 gallons of water is being added to the mixture, the mixer is kept running for approximately 3 to 5 minutes. The material is then fed from the mixer into the molds subjected to pressure, and removed for drying. Immediately following the mixing dry, approximately a gallon of water is added by means of the spraying process, then there is added the proper amount of ammonium stearate, and calcium chloride, and other ingredients, or the proper amount of stearic acid, and calcium chloride, and other ingredients. If the finished product is to be colored, the aggregate should be mixed thoroughly dry for approximately two minutes. It is then dampened by a line spray directed on to the materials in the usual concrete mixer, at an angle of approximately 45 degrees. Approximately one gallon of water should be applied at this time during the mixing process. Immediately following this mixing there is added about four liquid gallons composed of appropriate parts of water, mineral oxide, and the appropriate proportions of ammonium stearate and cal cium chloride, and other ingredients, or appropriate proportions of stearic acid, calcium chloride, and other ingredients, depending on the temperature of the operation, and the temperature of the material when it is being formed and set. In addition to the two minutes of dry mixing, this material should be mixed an additional 3 to 5 minutes during the spraying and dampening process.

The consistency of the aggregates should be such that when subjected to any of the above indicated processes of tamping, tamping and pressure, or pressure alone, no excess water or moisture escapes from the product.

The product is allowed to remain at an even temperature twenty four hours after being formed, but thereafter it can be removed from the building where the uniform temperature is maintained and stacked in the outside yards. It is ready for use one week after having been so formed.

It will be understood that we desire to comprehend within our invention such modifications as may be necessary to adapt it to varying conditions and uses.

Having thus fully described our invention, what we claim as new and desire to secure by Letters Patent, is

1. In a process of manufacturing a building material, pouring concrete, ammonium stearate and calcium chloride into a mold, subjecting the concrete to a blow to reduce it appreciably in thicknessand immediately withdrawing the molded product from the mold and allowing it to dry in the air.

2. In a process of manufacturing a building unit, pouring concrete into a mold, subjecting the concrete to a heavy blow to reduce its depth, subsequently subjecting it to a heavier pressure to still further reduce it in depth, holding the pressure an appreciable interval and removing the molded products from the mold.

3. In a process of manufacturing a building unit, pouring concrete into a mold, subjecting the concrete to a heavy blow to reduce its depth, subsequently subjecting it to a heavier pressure to still further reduce it in depth, holding the pressure an appreciable interval and removing the molded products from the mold, and drying in the air.

4. In a process of manufacturing a building unit, pouring concrete into a mold and subjecting the concrete to approximately seventy-five tons pressure, relieving the pressure and stripping the concrete from the mold in molded form and allowing it to dry in the air.

5. In a process of manufacturing a building unit, mixing concrete, ammonium stearate and calcium chloride, adding to the mixture mineral oxide coloring material, pouring in plastic form into a mold, subjectinv to a blow of approximately 1000 pounds, siibjecting to subsequent pressure of approximately seventy-five tons, relieving the pressure, and stripping the molded product from the mold and allowing it to dry in the air.

6. In a process of manufacturing a build ing unit, mixing concrete, ammonium stearate and calcium chloride, pouring in plastic form into a mold, subjecting to a blow of approximately 1000 pounds, subsequently subjecting the concrete to a pressure of approximately seventy-five tons, relieving the pressure, stripping the molded product from the mold, and allowing it to dry in the air.

7. In a process of manufacturing a building unit, mixing concrete, ammonium stearate and calcium chloride, pouring in plastic form into a mold, subjecting the plastic mass to a blow between 750 to 1000 pounds approx imately, subjecting the mass to a pressure of approximately 8 to 7 5 tons, relieving the pressure and stripping the molded product from a container in which it has been subjected to the blow and to the pressure.

8. In a process of manufacturing a building unit, mixing concrete, mixing ammonium stearate and calcium chloride therewith, pouring in plastic form into a mold and subjecting to pressure.

9. In a process of manufacturing a building unit, mixing concrete, mixing ammonium stearate and calcium chloride therewith, pouring in plastic form into a mold and subj ecting to pressure of from approximately 8 to 7 5 tons.

10. In a process of manufacturing a building unit, mixing concrete, mixing ammonium stearate and calcium chloride therewith, pouring in plastic form into a mold, striking a blow, and then holding under pressure for an appreciable interval.

11. In a process of manufacturing a bullding unit, mixing concrete, lubricating and waterproofing the mix, acceleratlng the mlx, settling and distributing the mix by a sudden blow, and forming the mix and causmg the agents of the mix by heavy sustained pressure.

12. In a process of manufacturing a building unit, mixing concrete, lubricating and waterproofing the mix, accelerating the mix, settling and distributing the mix by a sudden blow, and forming the mix and causing the intimate distribution and penetration of the lubricant, waterproofing and accelerating agents of the mix by heavysnstained pressure, and air drying the resulting product. 1

13. In a process of manufacturing a building unit, mixing concrete, lubricating and waterproofing the mix, accelerating the mix, coloring the mix, pouring in plastic form into a mold, preliminarily settling and distributing the mix by a sudden blow while in the mold, and then subjecting the mix to a relatively heavy and sustained pressure to cause distribution and penetration uniformly throughout the mix and adherence of the components of the mix for the retention of the form imparted by themold.

14. In a process of manufacturing a building unit, mixing concrete, lubricating and waterproofing the mix, accelerating the mix, coloring the mix, pouring in plastic form into a mold, preliminarily settling and distr1b uting the mix by a sudden blow while in the mold, and then subjecting the mix to a relatively heavy and sustained pressure to cause distribution and penetration uniformly throughout the mix and adherence of the components of the mix for the retention of the form imparted by the mold, and stripping from the mold and air drying.

In testimony whereof, we aflix our signatures.

HOWARD C. BYLAND.

FRANK L. ORMESHER.