Entitled: Composite Structural Member and Method for Making

Related Application

This is a continuation-in-part application of my piesently co-pending application Serial No 08/^62.881. filed November 27. 1995

BACKGROUND OF T HE INVENTION FIELD OF THE INVENTION

This invention relates to a composite structural membei and the method for making it In particular, it relates to a method tor encasing non-biodegradable compressible materials within useful stiuctural members, including but not limited to sound barriers, walls, seawalls and artificial teefs

DESCRIPTION OF THE PRIOR ART

As society becomes mote and more conscious of the high cost to the environment of disposing of unwanted mateiials within landfills, it becomes necessary to find more efficient and useful methods for disposal of these materials To date, recycling ol unwanted materials has been economical for only a few materials, such as steel, aluminum, waste papei . and some plastics Burning is limited due to the cieation of toxic fumes and the high cost of pioviding the scrubbers necessary to prevent the of such toxic fumes Therefoie. much of our waste ends up loosely scattered u ithin landfills oi stored in open storage sites This may be acceptable tor those waste materials that are readily biodegi adable. but those that aie not taint the soil for yeais to come

For instance, a particular problem is the disposal of rubber tires Currently, tires are stacked in the open air creating a fire hazard as well as an unsightly impact on the environment Improved methods for disposal of tπes include shredding the tires into small pieces chopping/grinding the tnes into granular sized pieces tor recycling and stacking compiesscd bundles in above ground storage areas Grinding the tires into small pieces

ioi iccycling is certainly the best solution, howevei the numbei of waste tires far exceed the demand foi gianulated tires Other methods of disposal include binding groups of them together and placing them in the ocean to piovidc a habitat tor fish Tues used in such artificial leefs iemain unsightly foi long periods of time as the rubbei does not biodegrade in salt watei

The patent to Nordberg, US patent 5, 103,616 discloses a method foi stacking tires axially on top of one another and compressing them into a bundle The bundle is then coveted with cυnciete to lorm constiuction blocks The axial alignment and cυmpiessiυn of the tires at relatively low pressures creates an inefficient bundle fiom which the block

Not withstanding the existence of such pnoi att, it lcmams clear that thcie is a need tor a system which will permit the disposal of a larger number of tires or other waste matei ials within an efficient composite structuial member

SUMMARY OF THE INVENTION The piesent invention lelates to a composite structural member and the method for making it, so that it encloses a large quantity of waste mateπal which otherwise would be discarded in a landfill The method foi making the composite stiuctural member comprises the following steps Compressing selected compressible mateiials under at least 107,000 pounds per square inch of pressure so that the mateπal is founed into a bale Then holding the compiessed bale in bale foim while the bale is being handled The next step comprises encasing the bale in cementitious material to form a composite stiuctui al membei Theiefoie, the composite structuial member comprises a bale of compressible material that has been compressed under at least 107,000 pounds per square inch of pressure, a holding means placed about the bale to prevent the bale from separating into the onginal separate components, particulaily tires, and a layer of cementitious material totally encasing the bale so that none of the compressible materials remains exposed

BRIEF DESCRIPTION OF THE DRAWINGS

Particularly piefened embodiments of the method and apparatus of this invention will be described in detail below in connection with the accompanying dtawings, in which.

FIGURE 1 is a perspective view of the composite stiuctuial member accoiding to the piesent invention

FIGURE 2 is a perspective view of a plurality of the membei s of Fig I . illustrating their placement to foi in a wall FIGURE 3 IS a fiont clevational view of the invention of Fig 1

FIGURE 4 is a tight side elevational view of the invention of Fig 1

FIGURE 5 is a fiont elevational view of the composite stiuctural membei illustrating the location of the bale within the member.

FIGURE 6 is a sectional view taken along line 6-6 FIGURE 7 is a perspective view of a second embodiment of the composite stiuctural membei ol this invention

FIGURE 8 is a sectional elevational view taken along line 8-8 of Fig 7

Si ilai lefeience characleis refer to similai paits thioughout the scvei a! views of the dtawings

DETAILED DESCRIPTION

A pieferred embodiment for the composite stiuctural member of this invention is illustrated in the diawing Figs. 1-6, in which the member is generally indicated as 10. A second prefeπed embodiment is illustrated in Figs. 7 and 8 m which the refeience numerals have been increased by an increment of 100 to indicate similai paits in these figuies Theielore, in Figs 7 and 8, the composite stiuctuial membei . of this invention, is indicated as 1 10 Refemng first to the view of Fig 5. it can be seen that the composite structural membei 10 comprises a bale 12 that is completely encased in a layer 14 of cementitious material.

The bale 12 may be comprised of any one or more compressible materials, including but not limited to cardboards, plastics, nonferrous metals, non-iecyclable papers, and t ubbei tues To piovide an illustrative example foi case of discussion, the compiessible materials illustrated in the Figs will be tues 16. however, the same discussion will generally apply to all other compiessible materials that may be used to produce the bale 12 The compressed tires 16 aie [held in a bundle] after compression by a [holding means,] conveniently at least one band 18 that extends longitudinally about the exterior surface of the bale 12 In othet embodiments the [holding] means 18 may comprise

a plui ahty of bands, a net like stt uctui c, a bag like sti uctuic 01 any othci similar means The bale 12 is encased in a cementitious layer 14 that includes, but is not limited to the f ollowing high compressive fly ash, bottom ash [sand and slag (fiom burning coal)] and conci ete For the purposes of this discussion, the cementitious layei 14 in the embodiment illustrated will be compi ised of conciete The layer of conciete 14 may be applied to the bale 12 simply to letain the compacted shape and provide an improved appeal ance, or in other embodiments, as illustrated in Figs 1 -8, to pi ovtde composite stiuctural members 10 The sti uctuial membeis 10 may be constructed m many different shapes and sizes to suit a paiticular purpose To construct as economical a membei 10 as possible, a layer 14 of conciete of minimum thickness is applied to the bale The layer 14 must be sufficiently thick to piovide the necessary strength and shape to meet the requπ ements for the finished composite structural member 10

In the embodiment disclosed in Figs 1 -6, the member 10 is formed as a structural member, so that a plurality of members 10 may be used for construction of a wall, as shown in Fig. 2 or foi other purposes to be discussed further below. In this preferred embodiment, to stabilize the members 10 a tongue and groove system is foimed on and in, respectively, the exterior surface 22 of the member 10 In Fig 1 , it can be seen that the membei 10 is comprised of a front face 24, a back face 26, and a plurality of sides 28 extending there between In the embodiment illustrated in Figs 1-6, the stiuctui al member 10 compnses four sides 28a-28d, however, in other embodiments, the member 10 may be compiised of any number of sides and any number of faces that is suitable foi the purpose for which the member 10 is intended The four sided member 10 lllustiated in Figs 1 -6 is paiticularly suitable foi the constiuction of walls, tiaffic baiπei s. dams, and so foi t As seen in Fig 1 , a tongue 30a is formed on the surface 22 of side 28a and extends outwaidly therefrom A tongue 30b is also foimed on the extenor surface 22 of side 28b, a side that is adjacent to side 28a The tongues 30a and 30b may be ot any length, and as shown m Fig 1 . extending longitudinally almost the full length of side 28a and 28b to provide the maximum stability In the exterior surface 22 of sides 28c and 28d, a groove 32c and 32d iespectively, is formed The giooves are sized and configuied to receive a tongue 30 of a dtffeient member 10 snugly theiein As shown in Fig. 2, the tongues 30a of the lowei blocks 10b and 10c are received in the groove 32c of the upper block 10a In like fashion, the tongue 30b of member 10b (not show n) is received by the gi oove 32d

of membei 10c ( not shown) In this fashion, a stable wall can be built fiom a plurality ol membei s 10

As also seen in Fig 1 , a pair of slots 34 aie formed in the side 28C extending through the membei 10 fiom the front face 24 to the back face 26 These slots 34 are sized and configured to receive the tines of a foiklift (not shown) for easy lifting and eι ιng of the members 10 Fiequently, a veitical lift may be lequired; therefoie, a lilting point 36 is funned in the tongue 30A lot attachment of lifting cables (not shown) The lifting point 36 is constiucted by inserting leinforcing bar within the tongue 30a and exposing the central poitton of it, as shown in Fig 5 As seen in Fig. 6, icinfoicmg bars 38 and steel mesh 40 may be inserted within the layet of concrete 14 to piovide additional strength as needed

A second pieferrcd embodiment of the composite structural member 10 is illustrated in Figs 7 and 8, in which at least two holes 142 aie foi med thiough the member 1 10 The holes 142 are spaced apart fiom the bale 1 12 so that the bale 1 12 remains encased within the layer of concrete 1 14 The remaining structure of structuial member 1 10 is essentially the same as structural membei 10 as identified by leference numbers 1 16- 132 In this embodiment as shown Figs 7 and 8 slots 34, lifting point 36, reinforcing bars 38 and the steel mesh 40 are not shown, but may be provided as lequired.

Having thus set foith two preferred embodiments for the structural member 10 of tins invention, it is to be remembered that these are only preferred embodiments Attention is now invited to a description of the method of making the composite structural members 10 Fu st, a determination of the type of structui al membei that is l equued for the particular use must be made As these structuial members 10 may be used foi construction of walls, levetrnents, and so forth, their configuration may vary accordingly For example, in the embodiments illustrated, the members 10 have been generally rectangular in shape, howevei , for constructing revetments, stiuctural members that aie six-sided may be used to more r igidly attach a plurality of membeis 10 togethei on a genei ally sloping surface For illustration purposes, a rectangulai member 10 will be descnbed, however, othei shapes aie generally made in the same mannet and may be easily constructed by peisons skilled in the ait The size and shape of the bale 12 will cieate limitations with legard to the shape and size of the member 10 The bale 12 may be constructed of many diffeient types of compressible matei ials Those materials for which landfill disposal is

undesi ible, including but not limited to plastics, nonfeπous metals, cardboai ds, and other non-iecyclable papers aie particulaily suitable Foi illustrative p i poses. the di awings and the description will lllusti atc using l ubber tues υl any type and size as the compiessible material 16 Rubber tues 16 aie placed within a full body honzontal baler that is capable of applying compiessible foices ovei 107,000 pounds Such balet s aie well known, for example the ECO-SYSI EMS BALER Model No 10895 The lues are placed geneially l ndomly within the baler, so that they are not axially aligned, to obtain a high level of compaction by allowing the lues to fill the majonty of the voids dunng compaction. In a preferred embodiment, the compaction piessure applied by the baler is greater than 107,000 pounds pet square inch (psi) In a pieferred embodiment, the compaction piessuie lies within the l ange of 107,000 psi to 135,000 psi

Application of a compaction pressure gi eater that 107,000 psi destroys the integrity of the rubber fibers and the metallurgical structure of the tire body so that the tires lose then "memoiy" Losing the tue body "memory" means that the tire bodies will not attempt to expand in ordei to return to their original shape The destruction of the tires "memory" is essential foi efficient compaction o{ tne bodies At pressures below 107,000 psi, some tires will have retained their "memory" and will begin expanding as soon as the compaction ram is withdrawn Such "rebounding" enlarges the bale of tires until the tires engage a iestraining means Such rebounding causes a significant reduction in the amount of tire that may be plated within a specific sized structural member.

Tires that have not lost their "memoi y" aie held in a bale by a iestraining means, for example metal bands Over time, the cementitious layer will ciack allowing moisture to con ode the bands Upon failure of the bands, the uibber tires will expand to their onginal shape causing major failure of the composite structural membei If the tires have lost then memories, they will not expand and the use ful life of the composite members will be significantly extended after cracking occurs Compaction piessui es greatei than 107,000 psi and the non-axial placement of the tues within the baler reduce the original volume of tues prior to compaction by 80 to 95 peicent A member 10 that is four (4) feet by four (4) feet by eight (8) feet holds a bale that is formed of approximately 147 standard automobile tries weighing a total of approximately 2.800 pounds using compression pressuies approaching 135,000 pounds per square inch Tires could be cut or chopped into smaller pieces, but the efficient compaction achieved under these methods makes the costly

operation of cutting and chopping unnecessary

Aftei compression of less than 107 000 psi has taken place, at least one band 18 is vvi apped longitudinally about the compiessed t ubbei tues 16 to lorm a bale 12 In a prefeiied embodiment, a plurality of bands 18, comprised of high tensile steel to withstand the ptessuies exeited by the tues 16 as they attempt to re expand, are used Olhei methods of containment that aie suitable foi the puipose include bagging, netting or cables When the tues aie compiessed at pressuies gteater than 107 ,000 psi the tues are held in bales by a holding means, conveniently bands made f rom steel or any othci mateπal that is strong enough to hold the tues in bale shape The holding means will not have to oveicome the foi ces created by expanding tues as the tires will have lost their memoiy The cross sectional size and shape of the baler, obviously dictates the general cioss sectional shape of the bale 12 If thin stiuctuial members are required, a baler having a thin cross section will be necessai y

The layer of cementitious material 14 may be applied to the bale by spraying it on , however, to provide structural members with a formed shape, the pieferred method is to place the bale within a set of forms that are designed for the paiticular stiuctural member desired Concrete, oi other cementitious material is then poured within the forms and about the bale 12 according to well known construction practices The forming of structural membei s by casting concrete within forms is well known in the art, and those skilled in the ai t will have little difficulty in casting the concrete into the shapes shown in

Figs 1 -8 It is onlv essential that the bale 12 be positioned so that it is completely encased by a layer of concrete that ts sufficiently thick to withstand the foices that it will leceive during its particular use Engineering analysis will be necessary to determine the amount of steel necessaiy and the height of the walls that will be pei mitted with any particular shape or size The high level of compaction attained at piessuies greater than 107,000 psi, will cieate a member that is able to withstand higher compiessive forces than members created at lowei pressures When the cementitious layer flexes under load, it will not greatly compress the dense bale of tires providing significant suppoit and preventing failure A wall of much gteater height can be constructed from membei s whose tires were compressed at piessuies over 107,000 psi, than a wall constructed of membei s foimed using significantly lower pressures

For the embodiments illustrated in Figs I 8 a tongue and giouve system is formed

to interlock the structural membei s 10 01 1 10 with one another To enable the use of a single sti uctural member design, it is necessaiy that the tongues 30 be f ormed on adjacent sides and the grooves 32 foimed on opposed adjacent sides

Different types of cementitious matei ials may be used, such as high compressive fly ash. bottom ash that may consist of a mixture of sand and various slags, particularly slag t esulting from coal burning Care must be used when using matei ials other than conciete to ensure that the stiength is adequate for the purpose

I he embodiment illusti ated in Figs 7 and 8 will be lυi cd in the same fashion as that illustiated in Figs 1-6 The major difference will be the necessity for forming the two openings 142 that pass through the member 1 10 As member 1 10 is largely used in artificial reef consti uction, a pluiality of smaller holes may be foi med in the structural member 1 10 to piotect smaller fish fiom then predatoi s After the composite structui al membei s 10 and 1 10 aie iemoved fiom their forms and the clu ing completed, they are then leady for use Having thus set forth a prefeiied method of construction for the composite stiuctuial members 10 and 1 10, attention is now invited to a description of then use The composite structuial members 10 and 110 have improved characteristics ovei plain concrete structural membei s Compressed lubber and other compressed materials piovide increased insulation capability, both in I educed sound and tempeiature transmission Therefoie, the sti uctui al members 10 may be used as sound barπeis to piotect lesidential aicas fiom traffic or other noises In addition, the use of lighter weight materials in the core of the members 10 piovide a sti uctural member that is lighter and easier to handle and can then be used for traffic diversion and control, security bari iers and other like uses The use of non recyclable materials will dispose of unwanted waste materials and at the same time will l educe the cost of the sti uctui al membeis Other uses may include flood contiol dikes, tevetments foi rru taiy and civilian aircraft, residential and/oi com eicial walls, seawalls, fill material, retaining walls for bulk materials, dikes, damns, and as we have discussed above ai tificial offshoi e lecis

It will thus be seen that the objects set forth above, among those made appaient fiom the pieceding description, aie efficiently attained and, since ceitam changes may be made in the above article without depaiting from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings

shall be miei pretcd as illustrative and not in a limiting sense

It is also to be understood that the following claims ai e intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall there between. Now that the invention has been described.