WO2021177839A1 - Continuous wrapping technology (cwt) - Google Patents

Abstract

This invention utilises the technology of wrapping to enable blocks of waste products (cardboard, plastic, tyres and rubbish) and aggregate or pipe mould to be joined together and sealed to create a concrete pipe, concrete coated bale, surface, wall or building structure. Or in the case of the surface veneer, single waste tyres siting side by side. This involves baling the product into a symmetrical shape, gathering it together on a wrapping machine (Figure1-2) whereby it can be compressed, bound, and then wrapped together with a variety of wrap. Buildings can also be constructed with the use of an overreaching wrapper (Figure 9&10).The utility in this invention, apart from making safe and cost-effective use of otherwise useless waste products, is the adaptability and sustainability of it, as the stronger a certain area needs to be, the more it can be compensated by extra wrap.

Description

Title of Invention Continuous Wrapping Technology (CWT) Technical Field Mechanical, Construction, Civil Engineering; recycling waste products and constructing usable structures with these waste products and any available aggregates. Description of Invention [0001] This invention utilises the technology of wrapping to enable bags of aggregate, blocks and bales of/or loose waste products; like tyres, plastic products, cardboard, car shredder waste, refuse as well as any available aggregate to be bound together in a form that will give long term utility and usefulness. The bales can also be put through a mould where they are coated or sprayed with concrete, then wrapped on exit to consolidate, enhance and strengthen the concrete coating. A continuous concrete pipe can also be constructed using this process. [0002] The wrapping enables the bales or bags to be coherently joined and sealed together to create a surface, wall, mound, artificial reef or building structure. [0003] Or in the case of single tyres laying horizontally side by side, a surface veneer and cylinders. Background Art [0004] Wrapping is used for two main purposes; sealing and storing foliage crops like grass silage, grain foliage and grains, as well as sealing and securing goods for transport. Despite extensive research, I have been unable to recognise any situation where wrapping is used like this for construction. [0005] As stated in another patent I, D.J.Williamson, am the owner of "Method of utilising tyres," PT761462 IPONZ and WIPO IB2020051003. The disposal of end of life tyres (ELT) has become an endemic and escalating problem in the world and the only consistent economically viable means of this is incineration for electricity production. Apart from being extremely wasteful (in that only about 45% of the energy used to make the tyre is recovered in electricity) this process is also extremely polluting releasing CO2 and many toxic gases and heavy metals. China took the vast bulk of the world’s waste plastic and cardboard until 2015, however this was halted by order of the Chinese government meaning huge amounts of plastic and cardboard waste is left with no use. [0006] Refuse waste is the cause of ongoing leachate and pollution problems. In vulnerable situations, this could be wrapped, bound and sealed posing no further toxic polluting potential, as well as mitigating any other negative effects of refuge dumping. Furthermore, the by-product of waste automobile shredding is proving a great difficulty to safely dispose of, so this process could safely and cost-effectively incorporate such waste in with other products and be put to a viable and sustainable use. [0007] Part of the difficulty in recycling plastic, cardboard, and paper, is the cost of ensuring they are consistent in grade, as well as completely clean. As CWT has no such requirements, it would offer a viable and cost-effective alternative to this escalating problem. [0008] Baled tyres have been used as road foundations in swampy and peaty areas. However, the bales have not been bound together, so I suspect success is limited due to the tendency of each individual bale to move, thus compromising the structure’s cohesion and stability. [0009] End of Life Tyres (ELT) have been used to create an artificial reef in Florida, USA. Unfortunately, they were fastened together with steel bands which did not prevent each tyre from constantly moving and being corroded to the point where they eventually broke free and were the cause of a huge environment disaster. The CWT process would prevent both of the issues which contributed to the problem. A further finding from the Florida reef was that sea life could not grow on naked ELT, another problem CWT would alleviate. [0010] Individual sausage-shaped bags filled with aggregate have been used for erosion control and recreational ammenities, such as surfing enhancement projects. As these have been deposited separately, this has left them vulnerable to the powerful ocean forces. Summary of Invention [0011] The product due to be wrapped is baled or bagged, then deposited on a machine similar to a foliage wrapping machine but strengthened and modified in order to bear the extra weight. It is also modified to enable it to compress and bind the product together before it is wrapped with a variety of different products depending on use and situation, including: wire, plastic, rip stop nylon, and products like kevlar. [0012] Building structures can also be constructed with the use of overreaching wrapping machines and arch technology. The utility of this invention lies in its adaptability and sustainability, as the stronger a certain area needs to be, the more it can be compensated by extra and stronger wrap. [0013] The baling is conducted with a conventional industrial baler. Auto shredder and plastic granule waste can be included in the bales as a means of dealing with these products. Ballast in the form of sand and/or fly ash can also be included in the tyre bales to make them heavier and denser if required. Technical problem [0014] One of the main problems in utilising these waste material bales for construction has been the difficulty in joining and securing them together, exacerbated by ramifications of the anticipated failure of the artificial reef constructed with ELT (as mentioned above), as well as the tyre bales floating and rising to the surface individually. [0015] The release of toxic leachate from such waste material. [0016] The need for consistent clean product. [0017] The lack of critical mass of bags when involved in coastal and river erosion control. This means they are eventually dislodged and become useless for purpose and a menace to the environment. In the case of the surfing enhancing project, the dislodgement and movement actually created a potentially fatal hazard, requiring a multimillion-dollar bill to mitigate. [0018] The difficulty in coating bales with concrete due to the unstable nature of the surface of the bale means it is not a feasible option at the moment as the concrete out covering will crack and break off. Solution to problems [0019] The process of CWT is similar to the use of mortar with bricks. Both of these materials were of little use by themselves, but when combined together became one of modern civilisation's icons. Most importantly, CWT will enable the products to be securely, sustainably and cost-effectively joined together in perpetuity. [0020] The wrapping will enable all toxic products to be permanently and confidently sealed. [0021] Any waste in any condition can be wrapped and the resultant product made good economic use of. [0023] The process enables any amount of critical mass product to be deposited in any area, plus it can be easily substituted and repaired if needed. [0024] The bales can be wrapped in different gauges and layers of material to enhance strength and stability, similar to a medical plaster caste. They can also be completely sealed until the concrete coating has cured. Once cured, the wrapping and concrete will create an unbreakable and impenetrable out coating which will last for, if necessary, perpetuity. This will be ideal for erosion control and construction. Description of Embodiments [0025] The products are baled using conventional baling apparatus (bales are typically rectangle cubes, 1300mm x1100x800 and weigh 500-1000kg. Both size and weight are adjustable) or bagged (bags can be any size, determined by ease of movement) in nylon bags. [0026] The bales or bags could then be individually wrapped or placed directly on modified wrapping machines (Figures 1&2) which have been strengthened and modified to accept the increased weight. The bales (or bags) are then either horizontally or vertically compressed together with compressing plates, then bound by wire, steel band or nylon tape. If additional strength is required, steel bars can be drilled through the bales and bolted at each end. This bound or bolted material is then fed through the wrapping machine and further bound together, then fed out as a single unit. [0027] The wrapping machines can be either a standard tube wrapping machine or the chain wrapping machine, whereby the size and shape can be adjusted. [0028] In the situation where extra width is required the chain wrapper's direction of wheels will shift 90 degrees. (Figure 3) can be used which will give surface coverage of up to 9 metres in width and a number of these apparatus can be joined together to give any desired width of one complete surface. [0029] The strength and durability of the wrapped product can be adjusted by adding re- bar and reinforcing mesh pre-wrapping. The bales or tyre cylinders can also be covered in concrete either through a mould or with a spray-on concrete application, then wrapped to cure. Industrial Applications 1) Continuous Concrete Pipe (Figure 17) [0030] A large proportion of the cost of laying concrete pipe is in the transport of the individual pipe portions. The embodiment of this invention allows the construction and laying of concrete piping on a continuous basis, meaning only the materials for construction need to be transported to the site, thus considerably reducing the bulk and cost. [0031] The pipe mould (that can be plastic, cardboard or steel) is fed through an extruder which coats it in concrete. The pipe, which is now covered in concrete is extruded and is wrapped in a plastic/nylon sheet to seal it. [0032] Strength and durability can be enhanced by using different layers of a different gauge of fabric so the concrete can impregnate the fabric to enhance strength, as well as spraying with extra concrete. 2) Low shock surface for walking or training track, athletic surface or dairy farm track (Figure 11) [0032] A foundation of wrapped bales is laid in the excavated trench. On top of this a surface veneer is laid (Figure 6) described below in example 3. Over this is laid a removable outer covering made from recycled plastic, carpet or rubber mat made from tyre crumb. [0033] This surface will be shock absorbent with all-weather capability. It will remain consistent, durable and stable all year round (with the exception of the top removable covering, which is easily replaced), will not wear out (apart from uses mentioned), and it will be ideal for horse training and exercise arenas. 3) Surface Veneer Composed of Waste tyres (Figure 6) [0034] The tyres are laid side by sided on reinforcing mesh. They are then fastened together by wire, nailed together and then filled with either rubber crumb from waste tyre processing or aggregate depending on the application. [0035] This is levelled over and put through the wrapping machine where it is wrapped and extruded out on the ground as a surface covering. 4) Concrete coated bales [0036] The baled waste tyres, plastic, cardboard or other waste are fed through a mould whereby they are encased in concrete. [0037] Upon exit, the complete bale, including the concrete, is then wrapped in geo-tech fabric to provide strength and encase the whole block. [0037] Plastic or nylon fabric can also be wrapped around the concrete coated bale to maintain the form of the block until it has dried and cured. [0038] The strength and durability can be enhanced by increased layers of fabric similar to a medical caste. These layers can be covered by spray-on concrete if required. 5) Prevention of desertification [0039] This involves filling rip-stop nylon bags with sand or other on-site aggregates, then compressing and wrapping them together. This is similar to the other wrapping of tyre, plastic and cardboard bales. [0040] This technology can be applied to either fences/barriers or tracks and surfaces. 6) Buildings (Figure 9) [0041] This entails the walls to be connected with an arch structure constructed from bales and arch spacers [0042] In order to maintain the arch, the walls will need to be stiff, which the wrapping will provide. [0043] If required, a horizontal stabiliser beam between the two walls can be used, but this will compromise the working height. [0044] Arch spacers can be made with recycled plastic and will mould into the bales to construct the required shape. [0045] Initially the arch is constructed with inner scaffolding with rollers on it so it can be moved through as the arch is completed. [0046] Concrete can be sprayed on it for extra strength. [0047] A much lighter material, like plastic or cardboard, could be used for the roof but the economics of this will depend on logistics. [0048] Buildings can be constructed by using wrapped surface and walls but still using a conventional roof structure (Figure 10). [0049] The wrapping system used for this is different from constructing the walls and surfaces, as it is overarching rather than rotational. [0050] Apart providing a sustainable and environmentally benign use for waste products, these building structures will be excellent in areas prone to climate extremes, both hot and cold, because of the insulation offered by the bales. In areas of abundant aggregate like deserts, the wall can be reinforced like noise barriers (Figure 8). 7) Foreshore protection and artificial reef (Figure 12) [0051] Coastal erosion and inundation has become a huge problem globally and this will continue to increase with anticipated sea-level rise as a consequence of climate change. [0052] The most expensive and complicated portion of adopting CWT for coastal erosion protection and artificial reef creation is the construction of the machine to install it, but obviously, once this is done it can be used many times over in many locations. [0053] Damaged areas of the artificial reef and foreshore can easily be repaired. The artificial reef can also be used to enhance the recreational surfing amenity (Figures 13&14). [0054] The present foreshore protection involves bags filled with sand which resemble the shape of a sausage, but these are subject to damage and displacement because of their size. This problem is easily alleviated with CWT as any particular areas that are damaged can be easily repaired and supplemented. [0055] There are many areas globally which are getting washed away despite the barriers placed in front of them (usually rocks). Rocks make the situation worse by deflecting energy, whereas the artificial reef constructed by CWT will absorb the energy, and when placed out to sea will break the swell, so that energy is dissipated before it reaches the shore. [0056] Surfing enhancement has been tried before using bags of sand, but these moved and created potentially fatal hazards with rips and undercurrents. [0057] These artificial reefs could also be used as tsunami protection. At present concrete star-like structures are used, especially in tsunami-prone areas like Japan, but these are expensive to make and difficult to transport. 8) Land reclamation (Figure 15) [0058] As there is a shortage of flat land around cities and ports, land reclamation is seen as a solution. Many ports are needing to become deeper due to increasing draft of ships so dredging ports areas has become more prevalent. Much of the tailings of this dredging contains toxic and hazardous substances but with the use of CWT these dredge tailings can be used to reclaim the land. [0059] After an artificial reef is constructed and the foundation laid, water can be pumped out. Tailings can either be dumped directly into the recess [0060] or bound, sealed and laid consecutively on top of one another (Figure16). This will create a stable non-toxic area and surface. 9) Other economic uses [0061] CWT could be used in earthquake prevention foundations as well as a substitute for the portable armour used by the USA in desert combat zones. This would be stronger, safer and provide greater shock absorption and dissipation than the bags presently used. 10) Single waste tyres cylinder [0062] Single waste can be sewn together, then wrapped to created a strong, durable cylinder which could be used to store all kinds of toxic waste, from fly ash to nuclear waste (Figure 19). [0063] Strength and longevity can be further enhanced by putting the CWT single waste tyre cylinder through a concrete mould and wrapping the concrete exterior again. This would be a suitable option for the storage of nuclear waste. 11) Water Jetty or bridge (Figure 20) [0063] As the product of wrapping, waste bales by CWT would be buoyant if anchored to the ground and secured to the lake or sea bed. They could then be used for jetties and bridges. Buoyancy can be enhanced by adding cylinders of wrapped waste tyres. Brief description of drawings Figure 1: Wrapping machine in horizontal surface configuration. Figure 2: Wrapping machine in vertical barrier wall configuration. Figure 3: Extended width wrapping machine up to 9 metres wide. Figure 4: Single tubular tyres. Figure 5: Single tubular tyres reinforced wrapping. Figure 6: Surface veneer constructed of horizontally laid tyres and filling wrapped. Figure 7: Barrier of wrapped tyres indented into the ground and reinforced with rebar stake drilled through. Figure 8: Noise control barrier with 2 wrapped wall and soil or aggregated place between them. Figure 9: Building structure constructed with baled material and arch support and arch spacers. Figure 10: Building structure with wrapped walls and floor but a conventional roof. Figure 11: Track for exercise or dairy farm track with bale foundation and veneer over top with a replaceable outer covering. Figure 12: Foreshore protection with artificial reef. Figure 13: Foreshore protection with artificial reef and surfing enhancement top view. Figure 14: Foreshore protection and surfing enhancement side view. Figure 15: Land reclamation with artificial reef and tyre surface lining. Figure 16: Wrapped bags of dredge tailings or other solid fill. Figure 17: Continuous concrete pipe mould. Figure 18: Wrapped barrier made from different waste products. Figure 19: Hooper filler to filled wrapped tyre cylinder. Figure 20: Wrapped bales and single tyre cylinder to make jetty in water. Detailed description of Drawings Figure 1 Shows the wrapping machine in horizontal mode. This machine is similar to a foliage bale wrapping machine but is substantially stronger with compressing plates both sideways and long ways to compress the bales together. 1. bales 2. wrapping machine 3. rollers 3 a. horizontal compressing plates 4. wrapping material can be any type of material either for strength or water resistance Figure 2 The wrapping machine in the vertical barrier configuration. The bales are placed on the machine having already been compressed and bound together vertically. Then the push arm (5) forces them through the wrapper while the wrapping material consolidates and binds the bales together, so a complete barrier is extruded out of the machine (7). Figure 3 is a cross-section of a wider adaptable self-propelled wrapping frame. In order to transport these machines conventionally, they must not be more than 3 metres wide. However, this way the machine can be towed by using the removable draw bar (9) and when it reaches it job site this is removed and the wheels will rotate 90 degrees (8) so the length becomes the width. It will also be possible to join several of these machines together to make any desired width required. Figure 4 Is the single tyre cylinder (10) with sidewalls and beads can either be sewn or nailed together to enhance strength, then wrapped with suitable material depending on application (2). Figure 5 is the cylinder tyres with rebar (13) secured then wrapped with wire for greater strength and durability, as well as the other normal material to seal (4). Figure 6 Is the horizontal veneer covering the tyres which are laid horizontally (10 a.) on reinforcing mesh (13) and geo-tech material (14). Filling, either rubber crumb or aggregate (15), is compressed into the tyres and it is then wrapped and extruded in the normal way. Figure 7 A baled horizontal barrier (7) is indented into the ground with rebar or similar stake (10) drilled through the bales and into the ground to anchor and stabilise it. Figure 8 two horizontal baled barriers (7) are placed side by side with a gap between them. That gap is filled with soil or other aggregates (17) for noise protection. Figure 9 This is a barn structure made up of baled walls. The floor surface (7) in between is placed arch support (18) and lighter paper bales are used for the roof (18 a.). The plastic arch spacers are put in place while the structure is supported from beneath, then the whole structure is wrapped with an overarching chain-driven wrapper. Once the wrapping is complete the internal support is removed. Figure 10 Is a barn structure with baled walls (7) and floor (7 a). A conventional roof structure is used. Figure 11 Is a cross section of the exercise surface or dairy farm track. A surface of bales (7a) is laid out and topped with the wrapped veneer (18), then on top of that is the removable outer cover (19). Figure 12 Foreshore protection bales of wrapped aggregate are laid in the affected area (7C). On top of that are tyre cylinders filled with aggregate which are wrapped and secured as strongly as possible (10) from above the high tide mark (A) to below the Low tide mark (B). Just outside the breaker zone, an artificial reef is laid with bags of wrapped aggregate (7), covered in wrapped tyre cylinders that are filled with appropriate material depending on the conditions. Figure 13 Is an aerial view of an artificial reef structure (D) used to protect an erosion- prone foreshore (C), as well as surfing enhancement, whereby the wave direction (E) is channelled into an artificial reef arrangement which gently rises using wrapped cylinders of tyres and wrapped filled bags of aggregate (F). Figure 14 is the side view of the surfing enhancing foreshore protection artificial reef. Using advanced wrapping technology, it can be seen that the single tyre cylinder starts well before the low tide mark (B) and the artificial reef remains below the high tide mark (A). The cross-section shows the gradual rise of the wrapped tyre cylinders in line with the wave direction (E). Figure 15 Is a model of land reclamation where an artificial reef (D) of wrapped aggregate is laid above the high tide mark (A). Wrapped cylinders of fill and tyres are laid on the seafloor (F) behind the artificial reef and a veer surface is placed above them. The water is then pumped out and the resulting void is filled with dredge tailing or other suitable fill. A wrapped surface layer (H) is placed on top to seal it. The water can be either pumped out before or after the seafloor surface layer is installed depending on the situation. Figure 16 is a model of the wrapped surface layer (H). The wrapping material will not only consolidate and strengthen the dredge tailing but will also seal any toxins or other toxic fill. Figure 17 Is the continuous pipe mould. The segments (20) are placed in the far end and fed through the mould (23) where they are coated in concrete. When they exit the mould coated in concrete, they are wrapped (4) in a variety of products to create stability and enhance strength and flexibility (similar to a medical plaster cast). This could include a reinforcing mesh mould which is also coated in concrete for extra strength. This can also be sprayed with shotcrete concrete (21), then further wrapped for additional strength. Figure 18 Show a wrapped barrier with different products which are included to enhance stability (1) such as tyre baled (1a) cardboard and (1b) plastic. This means the heaviest product is on the bottom, thus balance and stability are improved. Figure 19 Is a method whereby the wrapped tyre cylinders can be filled with products from aggregate to toxic waste. A hopper (24) is fitted to an excavator machine (26) which uses an auger (23) to feed the product fly ash or similar material (25) into the wrapped cylinders (10). A rammer can be used to compact the product in the wrapped cylinder. Figure 20 The degree of buoyancy of each product and bale can be determined by the compression of the bale but in their natural baled state tyres, plastic and cardboard are at least 50% buoyant, meaning they can support a load equal to their own weight before they sink. If these are wrapped together securely and fastened to the ground (6) while extending out in the water (A1) and secured to the seafloor (6 a), they will act as a perfect jetty, pontoon or bridge. Buoyancy can be increased by adding wrapped single tyre cylinders on the three bottom sides and wrapping them into the entire structure.

Claims

_Claims 1. A method of construction, comprising; a baled, bagged or loose material; and a wrapping to bind these together. 2. Where in the process of claim 1, may be conducted by a modified wrapping machine using wrapping material comprising but not limited to: plastic; nylon; polypropylene; webbing; wire; steel mesh; and kevlar. 3. The resultant product of claim 1-2 being: a wrapped surface; barrier; wall; mould; artificial reef; building; cylinder structure; or concrete pipe. 4. An apparatus wrapping machine (Figure 1 & 2), the subject of claim 1-3, where the improvement comprises strengthening and being fitted with compressor plates (Figure 1 - 3a) to compress and bind the contents together before they enter the wrapping process. 5. The method /process and apparatus being the subject of claim 1-4; that can dispose of all forms of waste comprising: tyres; cardboard; plastic; glass; liquid waste; car shredder by-product; refuse medical waste; and nuclear waste; that can be baled and secured, then put to use. 6. An apparatus for wrapping bales and bags, comprising the wheels being able to turn at 90 degrees from towing position, in order for the length to become the width (Figure 3). 7. The said apparatus subject of claim 6, whereby; they are able to join together in width configuration to create any desired width. 8. A method whereby bales, bags loose material, and cylinders, comprising: tyres; plastic; cardboard; and paper aggregate mixed with any other product; can be fed through a mould (Figure 17) and coated with concrete, then wrapped with various gauges of material and sealed until cured. 9. The process similar to claim 8, but, including the bale, bag or cylinder being sprayed with concrete and sealed by wrapping. 10. The said process similar to claim 8, where; pipe moulds, either plastic, cardboard or steel, can be joined together and fed through the concrete mould and/or sprayed then wrapped for strength and left until cured. 11. A process whereby a hopper is attached to a machine with an auger feeding in the product, either; aggregate or waste products, into a tyre cylinder, then wrapped and sealed or coated with concrete and wrapped again (Figure 19). 12. A process, whereby; buoyancy can be increased in the bale, with the wrapped portion anchored to shore and the wrapped bales fed out over a water body then secured to the sea/lake floor or riverbed creating a floating structure for use as a wharf or jetty. 13. The product of claim 12, buoyancy can be increased by adding wrapped single tyre cylinders (Figure 20). 14. A method subject to the process of claims 1-12 whereby steel reinforcing is incorporated in the wrapping process, and/or the steel bar can be drilled through the bales then they are bolted at both ends and if required anchored into the ground (Figure 7). 15. A method whereby artificial reef portions of the process subject of claims 1-4 & 13 are laid in the ocean as foreshore protection and shaped in such a way as to enhance the recreational surfing and fishing resource (Figure 13 & 14). 16. A method of land reclamation with the process being subject of claim 14 whereby the water is sealed and removed then replaced by aggregate, dredge tailings or other waste products, filled, wrapped, sealed and secured with CWT (Figure 15 &16). 17. A floating apparatus comprising a wrapping machine similar to contents of claim 1-5 and equipped with the means to deposit the wrapped product on the lake, sea or river bed, or in the structure recited in claim 12, launch it into the water. 18. A method for construction of buildings, using bales comprising: arch supports; arch spacers; and a wrapping machine. 19. The wrapping machine, being a subject of claim 18, is modified to overarch the building structure. 20. The cited method of building construction, being the subject of claim 19, but where the roof section is modified to replace bales with a conventional constructed roof.