US20160032586A1 - Load bearing interlocking structural blocks and modular building system - Google Patents

Load bearing interlocking structural blocks and modular building system Download PDF

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Publication number
US20160032586A1
US20160032586A1 US14/815,854 US201514815854A US2016032586A1 US 20160032586 A1 US20160032586 A1 US 20160032586A1 US 201514815854 A US201514815854 A US 201514815854A US 2016032586 A1 US2016032586 A1 US 2016032586A1
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Prior art keywords
structural block
block
embedded
interlocking
structural
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Abandoned
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US14/815,854
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English (en)
Inventor
Mac Radford
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Just Biofiber Structural Solutions Corp
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Just Biofiber Corp
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Priority to US14/815,854 priority Critical patent/US20160032586A1/en
Publication of US20160032586A1 publication Critical patent/US20160032586A1/en
Priority to US15/970,669 priority patent/US20180346382A1/en
Assigned to JUST BIOFIBER CORP. reassignment JUST BIOFIBER CORP. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: RADFORD, WILLIAM
Assigned to JUST BIOFIBER STRUCTURAL SOLUTIONS CORP. reassignment JUST BIOFIBER STRUCTURAL SOLUTIONS CORP. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: JUST BIOFIBER CORP.
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/10—Lime cements or magnesium oxide cements
    • C04B28/12—Hydraulic lime
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2/04—Walls having neither cavities between, nor in, the solid elements
    • E04B2/06—Walls having neither cavities between, nor in, the solid elements using elements having specially-designed means for stabilising the position
    • E04B2/08—Walls having neither cavities between, nor in, the solid elements using elements having specially-designed means for stabilising the position by interlocking of projections or inserts with indentations, e.g. of tongues, grooves, dovetails
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/002—Producing shaped prefabricated articles from the material assembled from preformed elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/14—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B28B1/523—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement containing metal fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B28B1/525—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement containing organic fibres, e.g. wood fibres
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/0048—Fibrous materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/0048—Fibrous materials
    • C04B20/0068—Composite fibres, e.g. fibres with a core and sheath of different material
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/10—Lime cements or magnesium oxide cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
    • C04B41/5076—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with masses bonded by inorganic cements
    • C04B41/5084—Lime, hydraulic lime or magnesium oxide cements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E04B1/12—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements consisting of other material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C1/00—Building elements of block or other shape for the construction of parts of buildings
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C1/00—Building elements of block or other shape for the construction of parts of buildings
    • E04C1/24—Elements for building-up floors, ceilings, roofs, arches, or beams
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C1/00—Building elements of block or other shape for the construction of parts of buildings
    • E04C1/39—Building elements of block or other shape for the construction of parts of buildings characterised by special adaptations, e.g. serving for locating conduits, for forming soffits, cornices, or shelves, for fixing wall-plates or door-frames, for claustra
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C1/00—Building elements of block or other shape for the construction of parts of buildings
    • E04C1/39—Building elements of block or other shape for the construction of parts of buildings characterised by special adaptations, e.g. serving for locating conduits, for forming soffits, cornices, or shelves, for fixing wall-plates or door-frames, for claustra
    • E04C1/397—Building elements of block or other shape for the construction of parts of buildings characterised by special adaptations, e.g. serving for locating conduits, for forming soffits, cornices, or shelves, for fixing wall-plates or door-frames, for claustra serving for locating conduits
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C1/00—Building elements of block or other shape for the construction of parts of buildings
    • E04C1/40—Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/28—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of materials not covered by groups E04C3/04 - E04C3/20
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/29—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces built-up from parts of different material, i.e. composite structures
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2002/0202—Details of connections
    • E04B2002/0243—Separate connectors or inserts, e.g. pegs, pins or keys
    • E04B2002/0245—Pegs or pins
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2002/0202—Details of connections
    • E04B2002/0243—Separate connectors or inserts, e.g. pegs, pins or keys
    • E04B2002/0254—Tie rods
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C2003/023—Lintels

Definitions

  • the invention disclosed herein relates to particular construction materials, as well as processes for preparation and uses of such materials.
  • Such materials may be intended for use as structural elements, such as structural blocks, used in the construction of buildings and civil engineering structures.
  • the prior art also discloses blocks used in the construction of structures, such as houses and commercial buildings, which may have properties that are either insulating or load bearing.
  • WO 2014072533 discloses an insulating construction material with an alleged low thermal conductivity comprising vegetal additions, as well as to a process for preparation and to uses of such a material.
  • the invention disclosed herein relates to particular construction materials, as well as processes for preparation and uses of such materials.
  • Such materials may be intended for use as structural elements, such as structural blocks, used in the construction of buildings and civil engineering structures.
  • structural blocks When the materials are used in the production of structural blocks, such blocks may integrate load bearing capabilities together with insulating properties.
  • structural blocks are provided that may be configured to interlock with complimentary blocks in the construction of a structure.
  • an interlocking structural block comprising a plurality of members embedded within the block, one end of the member extending through one surface of the structural block and an opposite end of the member terminating partway within the structural block, a plurality of apertures extend within the structural block from a second surface of the structural block, the apertures adapted for engaging with an extending end of an adjacent structural block.
  • an interlocking structural block comprising a block body having opposed top and bottom surfaces, opposed side surfaces and opposed end surfaces, a plurality of members embedded within the block, one end of the member extending through the top surface of the structural block and an opposite end of the member terminating partway within the structural block, wherein the embedded members comprise material which is substantially non-compressible along its length and contribute to the load bearing attributes of the structural block under compression, a plurality of apertures extending within the structural block from the bottom surface of the structural block to the terminating end of an embedded member of the structural block, the apertures adapted for engaging with an extending end of an adjacent structural block, at least one perforated tube embedded within the structural block, and at least one conduit for accommodating electrical wiring, piping or utilities.
  • a system of auto-aligning interlocking structural blocks comprising a plurality of structural blocks, each block having opposed top and bottom surfaces, opposed side surfaces and opposed end surfaces, a plurality of members embedded within the block, one end of each member extending through one surface of the structural block with an opposite end of the member terminating partway within the structural block, a plurality of apertures extending through the structural block from an opposed surface,wherein the embedded member extending end of a first structural block engages with the aperture of a second block, such that the embedded member terminating end of the second block is in direct contact with the embedded member extending end of the first block.
  • a further aspect is the use of the interlocking structural blocks of the present invention in the manufacture of a structure.
  • FIG. 1 is a front perspective view of a structural block in accordance with the present invention
  • FIG. 2 is a bottom perspective view of the structural block of FIG. 1 ;
  • FIG. 3 is a bottom view of the structural block of FIGS. 1-2 ;
  • FIG. 4 is a top view of a structural block in accordance with the present invention.
  • FIG. 5 is a front perspective view of a structural block comprising conduits therethrough, in accordance with a preferred embodiment of the present invention.
  • FIG. 6 is a bottom perspective view of the structural block of FIG. 5 ;
  • FIG. 7 is a bottom view of the structural block of FIGS. 5-6 ;
  • FIG. 8 is a top view of a structural block comprising perforated struts in accordance with a preferred embodiment of the present invention.
  • FIG. 9 is a front view of the structural block of FIG. 8 ;
  • FIG. 10 is a side view of the structural block of FIGS. 8-9 ;
  • FIG. 11 is a perspective view of a structural block adapted to accommodate a tensioning system therethrough;
  • FIG. 12 shows various views and types of structural blocks adapted to accommodate a tensioning system
  • FIG. 13 is a perspective view of a preferred embodiment of a tensioning system comprising a hex swage tensioner
  • FIG. 14 shows various views and types of structural blocks adjoined together through a tensioning system
  • FIG. 15 is a top view of a structural block adapted to accommodate a compression strut
  • FIG. 16 is a front view of the structural block of FIG. 15 ;
  • FIG. 17 is a side view of the structural block of FIGS. 15-16 ;
  • FIG. 18 is a front view of another structural block adapted to accommodate a compression strut
  • FIG. 19 is a side view of the structural block of FIG. 18 ;
  • FIG. 20 is a back view of the structural block of FIGS. 18-19 ;
  • FIGS. 21-33 show various views of a construction of a building in accordance with the present invention using the blocks of the present invention.
  • the present invention relates to particular construction materials, as well as processes for preparation and uses of such materials.
  • any term or expression not expressly defined herein shall have its commonly accepted definition understood by those skilled in the art.
  • the following description is of a specific embodiment or a particular use of the invention, it is intended to be illustrative only, and not limiting of the invention, which should be given the broadest interpretation consistent with the description as a whole.
  • the construction materials of the present invention are intended for use in structural elements for building structures and civil engineering structures.
  • the materials are used in the production of structural blocks.
  • the blocks of the present invention may be designed so as to integrate compression and torsional load bearing capabilities with insulation properties.
  • FIGS. 1-4 illustrate structural blocks in accordance with preferred embodiments of the present invention.
  • each block of the present invention may comprise a body shape configured so as to allow it to interlock with other blocks when constructing a structure, such as a wall or house. Such design can provide further strength to the overall structure.
  • each block can accommodate one or more embedded member.
  • the member which may also be termed a strut in the art, may be embedded within the block or inserted during building construction and may contribute to the load bearing properties of the block, particularly compression loads.
  • One end of the embedded member may protrude out a given distance from one side of the block, while the opposite end of the embedded member may terminate partway within the block on an opposite side.
  • the embedded member may be flush with the surface of the block and a positioning device may also be used to align and join the members together.
  • a tube with directional clips may be used between blocks to grip the abutting member ends in adjacent blocks.
  • a recess or opening can be formed within the block and can extend from the terminating end of the embedded member within the block through to the surface of a side of the block, opposite to the side through which the embedded member protrudes.
  • the extended end of the embedded member may protrude from the block by a distance that is approximately equivalent to the depth of the recess within the block.
  • a block with a height of 8 inches may accommodate an embedded member that is 8 inches in length.
  • the protruding end of the member may extend 2 inches out from the surface of one side of the block, with the remaining 6 inches embedded within the block.
  • a recess formed within the block at the member's opposite end may be 2 inches in depth. The recess may extend immediately from the terminating end of the embedded member housed in the block, to the surface of the opposite side of the block.
  • a recess can be of a size, shape and may be spaced apart from one another so as to align with and accommodate the protruding end of an embedded member of another block.
  • Such an arrangement may be similar to an interlocking “pin and socket” arrangement and can function as a locating means for the purpose of accurately positioning a block with respect to an additional block(s) while also contributing to the load bearing attributes of the block under compression.
  • the protruding end of an embedded member of one block When the protruding end of an embedded member of one block is positioned into the corresponding recess of a second block, the protruding end of the embedded member may be in direct contact with the terminating end of the embedded member of the second block.
  • the blocks can be said to auto align, and the embedded members can be said to form a stacked structure forming a load bearing structural member.
  • a recess within the block may have a width that is some measurement greater than the width of the embedded member.
  • the width of the recess may be 1 ⁇ 4 inch wider than the width of the member, for example, 1 ⁇ 8 inches on either side of the recess (on each of the four sides when the block and recess are square), to accommodate ease of insertion of the protruding member of an adjacent block.
  • Any suitable binding agent such as lime mortar for example, may be used to bind the protruding end of an embedded member of one block into the corresponding recess of a second block. Such a bond, when formed, may be stronger than the block itself.
  • a molecular bond may be formed that can contribute to the load bearing or other structural properties of the block.
  • the load bearing capabilities of the block of the present invention may be several times greater than that of a hollow concrete block, and more similar to or exceeding that of a conventional stud-framed wall structure.
  • holes may be created on the block that may be positioned an equal distance between the embedded members. As illustrated in FIGS. 5-7 , the holes may be used to create a conduit to accommodate electrical wiring or other utilities inside, for example, a structure's wall. The holes may also be beneficial to the curing process, by exposing the block's interior, for example, to injected carbon dioxide. In an alternate embodiment, some strut members may be hollow and slotted. As illustrated in FIGS. 8-10 , in another embodiment, additional perforated tubes or struts may be incorporated in the blocks therethrough.
  • the composition of the member or strut itself may comprise any rigid material or mixtures thereof, with any preferences to materials used directed to cost considerations and load bearing capabilities of the material.
  • the embedded member may comprise any wooden material, such as fir, spruce, pine, cedar, etc.
  • the element may also comprise composites of organic or inorganic fibers, such as hemp or carbon fiber, etc.
  • the embedded member may comprise a blend of bio fibers and polymers, such as polyethylene, polypropylene or polyester. Some compatible metals may also be used.
  • a member or strut may also be hollow, such as a hollow square or cylindrical tube. Other materials may include metals, carbon fibre or composites, 3D printed or extruded plastics or any suitable structural members.
  • the block of the present invention may be adapted so as to be tension bearing as well. As illustrated in FIGS. 11-12 , a block may be further adapted so as to accommodate a tensioning system that can provide tension.
  • the embedded member of the block can accommodate a tensioning means though the length of the member, such tensioning means entering through the one end of the member and exiting through the other end of the member.
  • the tensioning means may be a cable, such as, for example, a tensioned non-stretch stainless steel cable.
  • the system may comprise a rod.
  • the tensioning end assembly can comprise a hex swage tensioner, in addition to the cable.
  • each block when assembled, can be aligned with the corresponding members of other blocks, to allow the passage of the tensioning means through multiple embedded elements and blocks.
  • Such a configuration provides a further fastening means for a structure comprising the blocks of the present invention.
  • a configuration may be tension bearing, in that the blocks may be adjoined together through tension suitable for non-vertical structural elements such as floors, walls, pitched or flat roof surfaces, etc.
  • an additional member which may be termed a compression strut
  • a compression strut may, for example, be placed approximately perpendicular between and in contact with a pair of existing members or struts integrated into the body of the block each of which accommodates a cable as tensioning means.
  • the application of the compression strut in this embodiment may assist in keeping the embedded member pair properly spaced, without needing structure inherent in the block material, keeping the adjacent pairs of tensioned struts and cable or rod essentially equidistant throughout their length.
  • strut caps may be set into a block over the protruding end of an embedded member, with the extending end extruding from the cap.
  • the tensioning means may be tensioned post construction, after the blocks have been aligned.
  • the tensioning procedure with regard to a roof may include the following steps:
  • the frequency of tensioning means may need be applied only as required, for example, every meter of the assembled structure, to form a floor, roof, or other non-vertical structure, or can be a wall.
  • compositions comprising hemp hurd, flax, hydraulic lime and hydrated lime may be environmentally sustainable, recyclable and may sequester carbon dioxide from the atmosphere, while providing exceptional insulating qualities.
  • a block of the present invention may have a length of 48 inches or more and may maintain ease of handling because of its lower density, for example, 300 kg/cubic meter.
  • the lime component may primarily act as a binding agent, holding the other components together.
  • any suitable binding agent may be substituted in instances, for example, when a stronger bonding agent may be required.
  • Suitable alternative binding agents can include polymer based agents, for example silica sand, pozzolans, polyester resins, or Portland or similar cement or plaster. Such alternative agents may also be used in combination with the lime component of the preferred embodiment.
  • the hemp hurd and fiber component can provide insulating properties, bulk, support and strength to the block and structural members in the block.
  • any alternate material or combination of materials that can provide similar desirable properties may be used in the alternative.
  • Some organic alternatives include fibrous materials, such as corn stocks, cereal grain, straw, etc.
  • Hemp hurd is a preferred material, primarily due to its insulating qualities in relation to the other fibers.
  • non-organic materials such as Styrofoam/polystyrene or non-recyclable plastics may be used. Such materials may also be used in a shredded form. Structural fibers (oriented cellulose strands, plastics, metal or carbon filaments) may also be incorporated or substituted.
  • the application of these non-organic alternatives may provide an additional advantage, in that such non-recyclable materials may be sequestered from the environment, or may add different qualities to the blocks (strength, conductivity, electrical or RF shielding, noise abatement, etc.).
  • composition of a preferred embodiment comprises hemp hurd, flax, hydraulic lime and hydrated lime.
  • the primarily fibrous-lime combination is organic and composed of bio-recyclable material. When the useful life of a structure that uses such blocks comes to an end, its components may be recycled. For example, the entire block may be ground up and remixed for further subsequent applications.
  • the components of the composition are also sustainable.
  • hemp hurd in addition to its favorable properties, is readily available in supply and grows very quickly with little water and fertilizer.
  • fibrous-lime composition of the preferred embodiment allows the building to “breathe”. Air and humidity can pass both in and out of the blocks at a very slow rate. No vapor barrier may be required to be used.
  • the composition may also be resistant to mold, termites and other insect pests.
  • a structure using the block composition of the preferred embodiment may allow for fire resistance, due to the properties of the hemp hurd and lime mixture, or other compositions.
  • the blocks of the present invention may be further coated with a lime finish.
  • a block of the present invention may be coated with several, for example five or more, coats of lime.
  • a structure using the blocks of the present invention can be bonded to become monolithic. Such properties can be especially beneficial particularly in areas prone to earthquakes, hurricanes or tornados.
  • Water proofing or moisture resistant properties may also be realized, particularly by use of the lime component.
  • the lime component can also allow a block of the preferred embodiment to “heal” itself. For example, a crack in the lime coating can close over time when it is subjected to moisture.
  • the carbon dioxide sequestration properties of a block that comprises the preferred composition of the present invention allows for the removal and sequestration of the greenhouse gas carbon dioxide from the Earth's atmosphere.
  • the hemp hurd component of the composition can sequester carbon dioxide at a rate of over approximately 20 tonnes per hectare as the plants grow.
  • hemp hurd-lime composition blocks of the preferred embodiment have the capability to capture/absorb over approximately 100 kilograms of carbon dioxide per cubic meter.
  • the lime component can use carbon dioxide to cure and set the mixture.
  • An average house comprising such blocks, for example, can capture approximately 13,000 kilograms of carbon dioxide during block production and can continue absorbing carbon dioxide for approximately 100 years.
  • the fabrication of the blocks of the present invention may be attained by means using a mold process.
  • the embedded members or struts may be cut to the desired length, such as, for example, 8 inches in length.
  • a hole may be drilled through the lengths of the bodies of those members that will serve as conduits for the tensioning means.
  • a desired number of struts and perforated tubes are placed into a mold at the desired positions, in a jig.
  • a mixture comprising the components of the block's composition may be combined and mixed.
  • the mixture may then be, for example, poured, sprayed or injected into the mold.
  • the composition may be compressed and/or heated and allowed to set.
  • carbon dioxide may be injected or passed by (or through conduits within) the curing block, which decreases the cure time.
  • the blocks may also be cured in an autoclave to control the temperature, humidity and carbon dioxide environment.
  • a lime coating may be applied to the inner and outer face of the blocks at time of manufacture which may increase the block strength and reduce construction finishing time.
  • the blocks of the present invention may be pre-manufactured and then cut as desired on site.
  • a structure and related building materials is also disclosed by the present invention, as illustrated in FIGS. 21-33 .
  • such building materials may include blocks as disclosed in the present invention. Consequently, the blocks used in the structure of the present invention may be load bearing, tension bearing and insulating.
  • the blocks used may be of standard building construction dimensions. Height width and length may vary, depending upon the application, orientation and desired insulation requirements.
  • the blocks used for the walls of a structure may be a standard 11′′ thick and 8′′ high, while varying in length.
  • Roof structure blocks may be 12′′ high and 16′′ wide.
  • the building materials may also be pre-manufactured prior to being transported to an intended building site for assembly.
  • a 1400 square foot house structure is provided by way of example below.
  • the wall blocks can be of a standard height and width, and may vary in the length.
  • the wall blocks may be a standard 11′′ deep and 8′′ high, and may vary in the length.
  • the total count below includes blocks that may be cut on site.
  • Total counts include blocks that may be cut on site.
  • Structural ties may be breathable and in one embodiment, may be made from 16 gauge stainless steel mesh.
  • the fasteners used should be compatible with lime construction and can include stainless steel or ceramic coated fasteners.
  • lime mortar or another suitable mortar may be brushed on all block faces that are adjacent to another block face. As a result, this can create a structure that is monolithic and sealed.
  • the interior walls of the structure of the present invention may be a lime rendering, which may be colored or have breathable paint applied over it. In an alternative embodiment, there is no further application required to the interior walls. In another embodiment, the interior walls may also be covered in panels of sheetrock, wood veneer or brick, preferably with approximately a minimum 1′′ air space constructed between the bricks and the interior paneling.
  • the exterior walls of the structure of the present invention may have a plain coat bio-fiber and lime finish applied. Such an application can add to monolithic quality and building strength with a more finished look and a non-fading or fading resistant color finish.
  • the exterior walls can have a mortar application, or “stucco look”. Such an application can also add to monolithic quality and building strength with a more finished look and a non-fading or fading resistant color finish.
  • typical wall siding brick veneer and other non permeable materials may be used, and should maintain a minimum 1′′ space from the block surface.
  • there is no further application required to the exterior walls, and the blocks may be formed with a decorative exterior surface on them.
  • the blocks may have embossed or patterned surfaces for decorative or other purposes such as sound absorption, water-shedding, light reflectivity and so on.
  • any roofing material known in the art may be used in conjunction with the roof of the present invention structure. If non-breathable material is used, there should be an approximately one inch minimum space between the non-breathing material and the roof block.
  • the roof may be coated, for example, with a 7 coat, 100 year lime finish.
  • the roof may further comprise bio-fiber breathable “clay-like” tiles which may not require an air space.

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  • Architecture (AREA)
  • Chemical & Material Sciences (AREA)
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  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Composite Materials (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Building Environments (AREA)
  • Buildings Adapted To Withstand Abnormal External Influences (AREA)
  • Reinforcement Elements For Buildings (AREA)
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US14/815,854 2014-08-01 2015-07-31 Load bearing interlocking structural blocks and modular building system Abandoned US20160032586A1 (en)

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US14/815,854 Abandoned US20160032586A1 (en) 2014-08-01 2015-07-31 Load bearing interlocking structural blocks and modular building system
US14/815,829 Abandoned US20160130809A1 (en) 2014-08-01 2015-07-31 Load bearing interlocking structural blocks and methods of manufacture
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WO2016015138A1 (en) 2016-02-04
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CA2899473A1 (en) 2016-02-01
CA2899476A1 (en) 2016-02-01
JP2017526841A (ja) 2017-09-14
US20160130810A1 (en) 2016-05-12
EA037767B1 (ru) 2021-05-19
CA2899579A1 (en) 2016-02-01
EP3175056A1 (en) 2017-06-07
AU2015296749A1 (en) 2017-02-23
EA201790299A1 (ru) 2017-07-31
JP6850951B2 (ja) 2021-03-31
US20180346382A1 (en) 2018-12-06
ES2914679T3 (es) 2022-06-15
PT3175055T (pt) 2022-05-27
MX2017001511A (es) 2017-12-12
EP3175055B1 (en) 2022-03-02
EP3175055A4 (en) 2018-01-03
JP2017528628A (ja) 2017-09-28
CA2899464A1 (en) 2016-02-01
KR20170041787A (ko) 2017-04-17
CA2899465A1 (en) 2016-02-01
EP3175055B8 (en) 2022-07-13
AU2015296749B2 (en) 2019-05-30
WO2016015136A1 (en) 2016-02-04
EP3175055A1 (en) 2017-06-07
US20160130809A1 (en) 2016-05-12
US20160244368A1 (en) 2016-08-25
AU2015296752A1 (en) 2017-02-23
WO2016015135A1 (en) 2016-02-04
CA2899476C (en) 2023-06-20
WO2016015139A1 (en) 2016-02-04
EA201790297A1 (ru) 2017-06-30
CN107109846A (zh) 2017-08-29
PL3175055T3 (pl) 2022-08-08
WO2016015137A1 (en) 2016-02-04

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