WO2020084581A1

WO2020084581A1 - System and method for generating customized bricks

Info

Publication number: WO2020084581A1
Application number: PCT/IB2019/059163
Authority: WO
Inventors: Sunil Dhondibhau KADAM
Original assignee: Kadam Sunil Dhondibhau
Priority date: 2018-10-25
Filing date: 2019-10-25
Publication date: 2020-04-30

Abstract

The present disclosure relates to method for manufacturing structural blocks, and more specifically, to a system (100) and method for manufacturing customized block by incorporation of raw materials. The system (100) can include a first mould (110) and customized mould (114). The first mould (110) can be adapted to receive a pre-determined proportion of raw materials (108) along with water. The received raw materials can be preserved in the first mould for a pre-determined interval of time allowing formation of an intermediate block by application of a first external pressure. The second mould (114) can be adapted to receive the intermediate block (112) and generate a customized brick (116) having the textures embossed on its surface upon application of a second external pressure and upon passing of a slurry mixture having at least a colour pigment and water proofing agent at a pressure.

Description

SYSTEM AND METHOD FOR GENERATING CUSTOMIZED BRICKS

TECHNICAL FIELD

[0001] The present disclosure relates to methods for manufacturing structural blocks, e.g. bricks, and more specifically, to a system and method for manufacturing customized block or structural blocks by incorporation of one or more raw materials.

BACKGROUND

[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

[0003] Most wall structures in buildings are fabricated either from wood, steel, or aluminum studs. These studs are usually covered by siding or a stucco lath. In most climates, construction of these buildings requires insulation to be placed in between the studs, increasing the cost of construction without adding to the structural integrity of the building. Likewise, the insulation and the construction materials themselves are inflammable. It is not uncommon that a building of this type has to be demolished if there is water intrusion due to flood or a hurricane.

[0004] Walls are also fabricated from some type of block structure, such as brick or cinder block that is held together by mortar. The construction of these walls necessitates the expertise of a mason to properly apply the mortar to the proper depth. The use of skilled brick masons increases the cost of construction of the buildings.

[0005] In present days for manufacturing bricks river or sea sand is required. However because of restriction of government theft of sand seen. Also, the sand is natural resource and because of using river sand there are observe effect on an environment the water level of well is going down and down. Second thing is that at the time of plaster work of multiple floor building accident is happens due to the fall of worker. After the plaster worker need to paint the building which is time consuming and complex. The whole process consumes very much time, money, and labor, also in this process happening of accidents due to high altitude of buildings.

[0006] The construction of a typical block or brick structure also requires the transportation of the prefabricated blocks to the construction location. There they are unloaded and placed in a configuration to form the walls of the structure. The walls are built in a running bond pattern, with a layer of mortar between each tier of blocks. Skill in the art of masonry is required because mortar must be properly placed between each block and under each level row of blocks in an equal spacing pattern. Likewise, wall construction is a very time consuming. Cinder blocks used in construction are hollow to allow for the insertion of such necessities as electrical and plumbing and the voids provide additional reinforcement and reduction of their weight. However, these voids in the blocks take up a large volume, leading to inefficiencies in transportation. Also, there is usually waste, since the blocks are usually ordered as pallets.

[0007] The construction of walls with factory formed concrete panels produces relatively little waste, but has the drawback of being very heavy and difficult to transport to the job site. They also require the use of special equipment, such as a crane to construct the structure. While the“formed in place” concrete wall construction overcomes these issues, this method is more time consuming and generates waste. After the concrete dries, the form must be disassembled and removed from the site. In both instances, the concrete panels lack attractiveness, are difficult to finish, and have a tendency to develop cracks.

[0008] However, there are various technologies or devices available to manufacture bricks or blocks but there is no device or method that manufactures structural blocks by incorporation of fly ash, cement, and a waterproofing agent as the components. Further, there are various bricks or blocks but requires the plasters after masonry work. Further, if the user wants carving work or design on the conventional bricks or blocks then the user have to pay extra for it, like pop work, tiling work, glass work. Additionally, there is no system or method that manufactures customized block or bricks as per user’s requirement. [0009] Therefore, there is a need of a device and method for manufacturing structural blocks by incorporation of fly ash, cement, and a waterproofing agent as the components. Further, there is a need of a brick or block that is compact, light-weight and does not requires the plasters after masonry work and high bonding in exterior texture which provides strength in construction. Furthermore there is a need of a brick or block with carving work or designed work to reduce complexity, time and labor effort. Additionally, there is a need of a system and method for manufacturing customized blocks or bricks as per user’s requirement.

[0010] As used in the description herein and throughout the claims that follow, the meaning of“a,”“an,” and“the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

[0011] In some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

[0012] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g.“such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non- claimed element essential to the practice of the invention.

[0013] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims.

SUMMARY

[0014] The present disclosure relates to methods for manufacturing structural blocks, e.g. bricks, and more specifically, to a device and method for manufacturing structural blocks by incorporation of fly ash, cement, and a waterproofing agent as the components.

[0015] The comparison of current technology and in proposed technology is given below.

[0016] Therefore, there is a need of a device and method for manufacturing customized blocks by incorporation of fly ash, cement, and a waterproofing agent as the components. Further, there is a need of a brick or block that is compact, light-weight and does not requires the plasters after masonry work and high bonding in exterior texture which provides strength in construction. Furthermore there is a need of a brick or block with carving work or designed work to reduce complexity, time and labor effort. Additionally, there is a need of a system and method for manufacturing customized blocks or bricks as per user’s requirement.

[0017] To solve the above problems, the present invention is achieved by the following solution:

[0018] An aspect of the present disclosure relates to a system for generating a customized brick. The system can include a first mould and customized mould. The first mould can be adapted to receive a pre-determined proportion of one or more raw materials along with water. The one or more received raw materials can be preserved in the first mould for a pre-determined interval of time allowing formation of an intermediate block by application of a first external pressure. The customized mould can include one or more textures. The second mould can be adapted to receive the intermediate block and generate a customized brick having the one or more textures embossed on its surface upon application of a second external pressure and upon passing of a slurry mixture having at least a colour pigment and water proofing agent at a pressure, wherein the one or more textures are provided on at least one internal wall of the second mould in contact with the intermediate block.

[0019] In an aspect, the intermediate product can be a hard unit composed of the one or more raw materials capable of being sliced in a pre-determined size.

[0020] In an aspect, the intermediate block and the customized brick can include a pre-defined shape and size of the first mould.

[0021] In an aspect, the customized brick can have a different shape and size than the intermediate block.

[0022] In an aspect, the first external pressure and the second external pressure can be applied using a hydraulic pump.

[0023] In an aspect, the slurry mixture can be passed using a hydraulic injector.

[0024] In an aspect, the one or more raw materials can be selected from any or combination of quartz sand, a fly ash, quicklime, a lime slug, gypsum, a lime (mineral), cement, and an aluminium powder.

[0025] In an aspect, slurry mixture can include any or combination of ingredients selected at least from crush sand, a stone dust, a fly ash, wall putty, cement, white cement, a hardening agent, an insulating material, and a plastic.

[0026] In an aspect, the proposed system further can include a heater or a oven to autoclave the customized brick generated to increase rigidity and tenability of the customized brick.

[0027] In an aspect, the customized brick can include one or more interlocking features to allow interlocking with one or more other customized brick forming a snap-fit assembly. [0028] In an aspect, the first mould and the second mould can be connected with a conveyer such that the customized mould receives the intermediate block using the conveyer

[0029] An aspect of the present disclosure relates to method for generating a customized brick. The method includes the steps of: receiving, at a first mould, a pre-determined proportion of one or more raw materials along with water, wherein the one or more received raw materials are preserved in the first mould for a pre-determined interval of time allowing formation of an intermediate block by application of a first external pressure and receiving, at the a customized mould comprising one or more textures, the intermediate block and generate a customized brick having the one or more textures embossed on its surface upon application of a second external pressure and upon passing of a slurry mixture having at least a colour pigment and water proofing agent at a pressure, wherein the one or more textures are provided on at least one internal wall of the second mould in contact with the intermediate block.

[0030] Other features of embodiments of the present disclosure will be apparent from accompanying drawings and from detailed description that follows.

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

[0032] In the figures, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label. [0033] FIG. 1 illustrates a system and method for manufacturing a proposed customized block, in accordance with an exemplary embodiment of the present disclosure.

[0034] FIG. 2 illustrates a first mould of the proposed system, in accordance with an exemplary embodiment of the present disclosure.

[0035] FIG. 3 illustrates a customized mould of the proposed system, in accordance with an exemplary embodiment of the present disclosure.

[0036] FIG. 4A-E illustrates different views of a proposed customized block, in accordance with an exemplary embodiment of the present disclosure.

DETAILED DESCRIPTION

[0037] Embodiments of the present disclosure include various steps, which will be described below. The steps may be performed by hardware components or may be embodied in machine-executable instructions, which may be used to cause a general-purpose or special-purpose processor programmed with the instructions to perform the steps. Alternatively, steps may be performed by a combination of hardware, software, and firmware or by human operators.

[0038] Various methods described herein may be practiced by combining one or more machine-readable storage media containing the code according to the present disclosure with appropriate standard computer hardware to execute the code contained therein. An apparatus for practicing various embodiments of the present disclosure may involve one or more computers (or one or more processors within a single computer) and storage systems containing or having network access to computer program(s) coded in accordance with various methods described herein, and the method steps of the disclosure could be accomplished by modules, routines, subroutines, or subparts of a computer program product.

[0039] If the specification states a component or feature“may”,“can”,

“could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.

[0040] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the disclosure to those of ordinary skill in the art. Moreover, all statements herein reciting embodiments of the disclosure, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).

[0041] Thus, for example, it will be appreciated by those of ordinary skill in the art that the diagrams, schematics, illustrations, and the like represent conceptual views or processes illustrating systems and methods embodying this disclosure. The functions of the various elements shown in the figures may be provided through the use of dedicated hardware as well as hardware capable of executing associated software. Similarly, any electronic code generator shown in the figures are conceptual only. Their function may be carried out through the operation of program logic, through dedicated logic, through the interaction of program control and dedicated logic, or even manually, the particular technique being selectable by the entity implementing this disclosure. Those of ordinary skill in the art further understand that the exemplary hardware, software, processes, methods, and/or operating systems described herein are for illustrative purposes and, thus, are not intended to be limited to any particular named.

[0042] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.

[0043] The present invention relates to a method for producing a lightweight block having a prescribed strength by mixing a fly ash, a small amount of cement and a waterproofing agent, homogenously mixing the mixture, molding a predetermined size brick by a high- And to provide a lightweight brick having high strength and excellent waterproof property without using sand. [0044] Aspects of the present disclosure relate to a proposed method disclose to incorporate fly ash, cement, and a waterproofing agent (in various quantities/parts by weight or percentages) as the main components; however, in addition to this, one or more components such as e.g. an insulating material (glass wool), and reinforcement material (plastic, etc.), and the likes can also be added to strengthen the quality/strength of the block.

[0045] In an aspect, the proposed method discloses to mix the components in a first mold/dye such as to form an intermediate block. Thereafter, the said intermediate block can be passed on to a second mold/dye or customized mould to give the required shape, texture, color, etc. Finally, a heat treatment, such as sintering or autoclaving, can be given to make the customized block for more rigidity and strength.

[0046] An aspect of the present discourse relates a proposed system for manufacturing a customized block. The system can include a first mould, a customized mould and heater or heating unit.

[0047] In an aspect, the customized block can be manufactured by raw materials. The raw material can be selected from any or combination of fly ash, cement, waterproofing agent, crush sand, water, quicklime or lime slug, cement, aluminium powder, gypsum.

[0048] In an aspect, the raw materials can be put in a first mould to form an intermediate block.

[0049] In an aspect, the intermediate block can then passed through a customized mould to provide a desired shape, size, and color, texture which is pre-defined or pre -configured or customized as per user’s requirement. The customized mould can form a customized block

[0050] In an aspect, the customized block can then passed through a heater or heating unit to increase rigidity and feasibility of the block. This process or step can be optional or desired as per user’s requirement.

[0051] FIG. 1 illustrates a system and method for manufacturing a proposed customized block, in accordance with an exemplary embodiment of the present disclosure. [0052] In an embodiment, the system (100) can include a stage one (102), stage second (104) and third stage (104).

[0053] In an embodiment, a proposed system (100) for manufacturing a customized blocks (hereinafter interchangeably referred as customized brick or brick or customized unit). The system (100) can include a first mould (110), a customized mould (114) and heater or heating unit (106).

[0054] Stage one- in an embodiment, the raw material (108-1), (108-2) and (108-3) (hereinafter collectively referred as 108) can be placed in a first mould (110) to form an intermediate block (112). The raw material (108) can be selected from any or combination of fly ash, cement, waterproofing agent, crush sand, water, quicklime or lime slug, cement, aluminium powder, gypsum. In an exemplary embodiment, the raw material (108) can be mixed or placed in pre defined or pre-configured or pre-defmed quantity.

[0055] Stage second- the intermediate block (112) can be passed through a customized mould (114) to provide a desired shape, size, and color, texture which is pre-defmed or pre-configured or customized as per user’s requirement. The customized mould (114) can form a customized block (116).

[0056] Stage three- the customized block (116) can be passed through a heater or heating unit (118) to increase rigidity and feasibility of the block and output as heat treated customized block (120). This process or step can be optional or desired as per user’s requirement.

[0057] In an exemplary embodiment, as the heating process is optional so the customized block (116) or heat treated customized block (120) can be output as per user’s requirement. If the user wants brick with heating then the heat treated customized block (120) can be output or required brick. If the user wants the customized block (116) then the customized block (116) can be required block or output of the system.

[0058] FIG. 2 illustrates a first mould of the proposed system, in accordance with an exemplary embodiment of the present disclosure. FIG. 3 illustrates a customized mould of the proposed system, in accordance with an exemplary embodiment of the present disclosure. [0059] In an embodiment, the proposed system can manufacture one or more types of bricks. The proposed bricks can be concrete bricks, fly ash bricks and autoclaved aerated concrete bricks / blocks.

[0060] In an exemplary embodiment, the concrete bricks / blocks can be manufactured by using crush sand, cement, water. In another exemplary embodiment, a mixture of the mentioned ingredient can be mixed as required strength as M10, M15, M20, M25, M30 etc. and pours in first mould (110) and presses it by hydraulic pressure (202) 150 to 200 psi, as shown in FIG. 2. After applying hydraulic pressure (202) wait for 24 hrs for rigidity of the brick. Remove the bricks from the mould and keep it in customized mould (114) for providing a desired shape, size, and color, texture which is pre-defined or pre-configured or customized as per user’s requirement.

[0061] In an exemplary embodiment, the Fly ash bricks / blocks can be manufactured by using one or more ingredients such as Fly ash, water, quicklime or lime slug, cement, aluminium powder and gypsum. In another exemplary embodiment, the said ingredient can be mixed with each other based on pre defined or pre-configured ratios. There are 3 ratios depend on market or material availability.

Ratios - 1 -

I. Fly ash - 50 to 60 %

II. II. Stone dust - 20 to 30 %

III. III. Sludge lime - 15 to 22 %

IV. IV. Gypsum - 5%

V. V. Water - 8 to 10 %

Ratios - 2

I. Fly ash - 57 to 65 %

II. Stone dust - 18 to 27 %

III. III. Hydrated lime - 9 to 12 %

IV. IV. Gypsum - 5 %

V. V. Water - 8 to 10 %

Ratios 3 -

I. Fly ash 50 to 60 % II. Stone dust - 30 to 40 %

III. Cement - 8 to 12 %

IV. Water 8 to 10 %

In another exemplary embodiment, the said ingredient can be mixed with each other based on pre-defmed or pre-configured ratios in first mould (110) and apply manual or hydraulic press (202) by 100 to 140 PSI as shown in FIG. 2. The strength and hardness of the bricks or blocks can be achieved by cement strength and instant curing mechanism by autoclaving.

[0062] In an exemplary embodiment, the C - Autoclaved aerated concrete bricks / blocks (LCC SIPOREX) can be manufactured by using one or more ingredients such as Fly ash, lime powder, cement, gypsum, aluminium powder, and water. The said ingredient can be mixed with each other based on pre-defmed or pre-configured ratios. There can be one or more ratios depend on market or material availability.

Ratio -

I. fly ash - 65 to 70 %,

II. Lime - 8 to 12 %

ITT Cement - 10 to 15 %

IV. Gypsum - 4.5 to 5 %

V. aluminium powder - 0.5 %

VI. Water - 0.60 to 0.65

In another exemplary embodiment, the said ingredient can be mixed with each other based on pre-defmed or pre-configured ratios and make slurry of above ingredients then add aluminium. After that pour the mixture in first mould (112). Cycle time for this procedure is 5.5 minutes. Keep it in mould up to 60 to 240 minutes. It depends on the raw material. Due to this pre-curing is also referred as ‘heating room pre-curing’ at the end of pre-curing process, green cake is hard enough to be wire cut as per requirement. Then cut the block as per our requirement size.

[0063] In an exemplary embodiment, one or more ingredients can be mixed with each other for formation of slurry (304) in second stage. The ingredients can be selected from any or combination of crush sand, stone dust, fly ash, wall puty, cement, white cement, colour pigment, hardening agent, water proofing agent, water. The ingredients can be mixed with each other based on pre defined or pre-configured ratios.

There are three types of base material with variable ratio.

Ratio - 1

I. Crush sand - 30 to 45 %

II. Stone dust - 30 to 40 %

ITT Cement - 15 to 20 %

IV. Colour pigment - 10 to 20 % (depends on colour shade)

V. Hardening agent - 2 to 5 %

VI. Water proofing agent - 2 to 5 %.

VII. Water - 10 to 15 %

Ratio - 2

I. Fly ash - 40 to 50 %

II. Stone dust - 30 to 35 %

ITT Cement - 15 to 20 %

IV. Colour pigment - 10 to 20 % (depends on colour shade)

V. Hardening agent - 2 to 5 %

VI. Water proofing agent - 2 to 5 %.

VII. Water - 10 to 15 %

Ratio - 3

I. Wall puty - 50 to 55 %

II. Stone dust - 10 to 15 %

III. Colour pigment - 10 to 15 %

IV. Cement - 15 to 20 %

V. Hardening agent - 2 to 5 %

VI. Water - 20 to 30 %

[0064] In an exemplary embodiment, the intermediate block (112) can be placed in to the customized mould (114) for the final finishing, as per pre-defined or pre-configured requirement such as variable textures and colors. First keep the intermediate block (112) inside the customized mould (114) and pass the slurry mixture (302) by hydraulic injector (302) as shown in FIG. 3. is also possible by vibration table but it has some limitations. So, the injector is a best solution to do this.

[0065] In an exemplary embodiment, when adding this waterproofing agent to concrete block or brick during the manufacturing process for same, it is typically introduced in liquid form and in a similar dosage. Thus, the present invention can be utilized to provide a masonry cement having waterproofing capabilities through the use of a dry waterproofing agent. In addition, the proposed blocks or bricks can be produced by introducing the waterproofing agent of the present invention in liquid form into the concrete blocks or bricks during the manufacturing process for same. The raw materials of the present invention containing the dry waterproofing agent can be added to water and sand forming a mortar for joining the proposed blocks or bricks containing the waterproofing agent to produce a wall structure having excellent waterproofing capabilities. It has been found that efflorescence is substantially reduced or eliminated in such wall structures since stearates, which wear away over time increasing the possibility of efflorescence, are not present, and moisture on the surface of the wall structure is minimized. Moisture, along with pressure and salts, is required in order to create efflorescence.

[0066] FIG. 4A illustrates a top view of a proposed customized block, in accordance with an exemplary embodiment of the present disclosure.

[0067] FIG. 4B illustrates a bottom view of a proposed customized block, in accordance with an exemplary embodiment of the present disclosure.

[0068] FIG. 4C illustrates a side view of a proposed customized block, in accordance with an exemplary embodiment of the present disclosure.

[0069] FIG. 4D illustrates a side view of a proposed customized block, in accordance with an exemplary embodiment of the present disclosure.

[0070] FIG. 4E illustrates a top view of a proposed customized block, in accordance with an exemplary embodiment of the present disclosure.

[0071] It may be appreciated that, Fly ash or flue ash, also known as pulverized fuel ash in the United Kingdom, is a coal combustion product that is composed of the particulates (fine particles of burned fuel) that are driven out of coal -fired boilers together with the flue gases. Ash that falls to the bottom of the boiler is called botom ash. In modem coal-fired power plants, fly ash is generally captured by electrostatic precipitators or other particle filtration equipment before the flue gases reach the chimneys. Together with botom ash removed from the botom of the boiler, it is known as coal ash. Depending upon the source and composition of the coal being burned, the components of fly ash vary considerably, but all fly ash includes substantial amounts of silicon dioxide (Si02) (both amorphous and crystalline), aluminium oxide (A1203) and calcium oxide (CaO), the main mineral compounds in coal-bearing rock strata.

[0072] Further, it should be appreciated that Fly ash is a by-product from the burning of coal in coal fired power stations. Fly ash is made in abundance and typically contains heavy metals such as cadmium, chromium, zinc and lead that make disposal problematic. In trying to minimize the environmental impact of fly ash, various uses of fly ash have been contemplated to both aids in fly ash disposal and to obtain some economic return

[0073] Accordingly, the invention provides methods of manufacturing articles from fly ash which can be produced on a commercial scale and which exhibit excellent properties both in terms of strength and absorption capacity which makes such articles ideally suited as a substitute for conventional clay bricks.

[0074] It may be appreciated that, the proposed blocks can be used for construction stable single wall or double layer or multiple layer walls and adjacent walls.

[0075] It should also be appreciated that once a wall or walls of the building blocks according to the present invention have been erected, they may be covered with a suitable outer sheathing or a brick veneer wall. Where bricks are used, tie-ins can easily be connected between the mortars joints of a brick veneer wall and any of the female sockets along the side of the wall, or the inverted V- shaped recesses.

[0076] In another usage, the proposed blocks can be used to form concentric pillars. For instance, if the ring or hollow cylindrical type of block has protrusions and/or grooves on the outer curved surface too, then another set of rings having complimentary features can further interlock with it. The inner diameter of this additional set of rings will be roughly equal to the outer diameter of the first set of rings. Several sets of rings can be added as long as they satisfy the condition that its inner diameter equals the outer diameter of the preceding block/ring and external diameter equals the inner diameter of the succeeding ring. The outermost ring will preferably be shaped similar to ring because there is no need to provide an interlocking feature (protrusion or groove) on the outermost surface. The diameter of the pillar can thus be extended to a desired size by adding more concentric rings in the same manner. This application is also useful for creating large diameter pillars without having to transport and construct very large and bulky bars or pillars.

[0077] It should be appreciated that, the proposed building blocks can form structures in almost any shape, so a complete house can be constructed faster than using conventional brick and mortar. The construction/ building thus formed using the blocks of the present invention are very strong, earthquake resistant and resistant to high winds. The blocks can be made fire proof, water proof, thermally insulating, electrically insulating etc. depending upon the part of the construction in which they are used. For providing electrical fittings and piping the hollow blocks can be used and assembled as per the requirements of the building.

[0078] The block can be made of any materials to suit the particular application. For electronic/ microelectronic circuitry, the block or particular surfaces can be made of base materials as is used in wafer foundry to manufacture semiconductors. Similarly for large appliances, the block can be manufactured using stronger metals or may even have multi-layered surfaces where the inner layers can house the circuitry and the outer layers can offer strength and bear the mechanical parts of the appliance.

[0079] The processes used to manufacture the blocks are dependent on the material of manufacture, the shape and structure of the material as well as the process economics. Ideally all manufacturing methods should be considered while deciding and the merits and demerits of each should be listed. Once this has been done, the process having the most economic efficiency over both the long and short term for the desired quality should be adopted to manufacture the product. [0080] It may be appreciated that binder or mortar a workable paste used to bind building blocks such as stones, bricks, and concrete masonry units together, fill and seal the irregular gaps between them, and sometimes add decorative colors or patterns in masonry walls. In its broadest sense mortar includes pitch, asphalt, and soft mud or clay, such as used between mud bricks. Mortar comes from Latin moratorium meaning crushed.

[0081] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word“comprising” is used in an inclusive sense, i.e. the features specified may be associated with further features in various embodiments of the invention.

[0082] While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the aspects of the invention. It is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby.

[0083] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms“comprises” and“comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C ... .and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc. The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the scope of the appended claims.

[0084] While embodiments of the present disclosure have been illustrated and described, it will be clear that the disclosure is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the scope of the disclosure, as described in the claims.

Claims

I Claim:

1. A system (100) for generating a customized brick (116), the system comprising:

a first mould (110) adapted to receive a pre -determined proportion of one or more raw materials (108) along with water, wherein the one or more received raw materials (108) are preserved in the first mould (110) for a pre -determined interval of time allowing formation of an intermediate block (112) by application of a first external pressure; and

a customized mould (114) comprising one or more textures, the second mould (114) is adapted to receive the intermediate block (112) and generate a customized brick (116) having the one or more textures embossed on its surface upon application of a second external pressure and upon passing of a slurry mixture (304) having at least a colour pigment and water proofing agent at a pressure, wherein the one or more textures are provided on at least one internal wall of the customized mould (114) in contact with the intermediate block (112).

2. The system (100) as claimed in claim 1, wherein the intermediate block (112) is a hard unit composed of the one or more raw materials (108) capable of being sliced in a pre-determined size.

3. The system (100) as claimed in claim 1, wherein the intermediate block (112) and the customized brick (114) comprises a pre-defined shape and size of the first mould.

4. The system (100) as claimed in claim 1, wherein the customized brick (114) comprises a different shape and size than the intermediate block (114).

5. The system (100) as claimed in claim 1, wherein the first external pressure and the second external pressure is applied using a hydraulic pump (202).

6. The system (100) as claimed in claim 1, wherein the slurry mixture (304) is injected using a hydraulic injector (302).

7. The system (100) as claimed in claim 1, wherein the one or more raw materials (108) are selected from any or combination of a quartz sand, a fly ash, a quicklime, a lime slug, a gypsum, a lime (mineral), a cement, and an aluminium powder.

8. The system (100) as claimed in claim 1, wherein the slurry mixture (304) includes any or combination of ingredients selected at least from a crush sand, a stone dust, a fly ash, a wall putty, a cement, a white cement, a hardening agent, an insulating material, and a plastic.

9. The system (100) as claimed in claim 1, wherein the system comprises a heater (118) to autoclave the customized brick (116) generated to increase rigidity and tenability of the customized brick.

10. The system (100) as claimed in claim 1, wherein the customized brick (116) comprises one or more interlocking features to allow interlocking with one or more other customized brick forming a snap-fit assembly.

11. The system (100) as claimed in claim 1, wherein the first mould (110) and the second mould (112) are connected with a conveyer such that the customized mould (112) receives the intermediate block (112) using the conveyer.

12. A method for generating a customized brick, the method comprising: receiving, at a first mould, a pre-determined proportion of one or more raw materials along with water, wherein the one or more received raw materials are preserved in the first mould for a pre-determined interval of time allowing formation of an intermediate block by application of a first external pressure; and receiving, at the a customized mould comprising one or more textures, the intermediate block and generate a customized brick having the one or more textures embossed on its surface upon application of a second external pressure and upon passing of a slurry mixture having at least a colour pigment and water proofing agent at a pressure, wherein the one or more textures are provided on at least one internal wall of the second mould in contact with the intermediate block.