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Title:
ENVIRONMENTALLY RESPONSIBLE INSULATING CONSTRUCTION BLOCKS
Document Type and Number:
WIPO Patent Application WO/2017/086932
Kind Code:
A1
Abstract:
Environmentally responsible insulating construction blocks constructed primarily of recycled materials are disclosed. The construction blocks comprise shredded rubber tire pieces coated with silica flume, slag cement and cement, which are then mixed with water and formed in a mold. The construction blocks can further comprise insulation foam disposed in the interior open matrix. The construction blocks provide high insulation as well as strength for applications such as roofing and wall construction, and other applications.

Inventors:
SPREEN, Richard D. (6742 N.W. 17th Avenue, Fort Lauderdale, Florida, 33309, US)
Application Number:
US2015/061055
Publication Date:
May 26, 2017
Filing Date:
November 17, 2015
Export Citation:
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Assignee:
THE SHREDDED TIRE INC. (6742 N.W. 17th Avenue, Fort Lauderdale, Florida, 33309, US)
International Classes:
C04B18/22; E01C5/06; E01C7/14
Foreign References:
US20030125425A12003-07-03
US20140087158A12014-03-27
Other References:
"Concrete Proportioning'' Slag Cement Association (SCA", 1 October 2013 (2013-10-01), pages 3, XP009506604, Retrieved from the Internet [retrieved on 20151231]
ONUAGULUCHI, O ET AL.: "Hardened properties of concrete mixtures containing pre-coated crumb rubber and silica fume", JOURNAL OF CLEANER PRODUCTION, vol. 82, 2 July 2014 (2014-07-02), pages 125 - 131, XP029018018, Retrieved from the Internet [retrieved on 20151231]
"Three-Inch Thick Paver Designs Available in the Opus Romano, French Versailles, Roman Romano, and Rome Opus Patterns", THE MOLD STORE, 3 April 2014 (2014-04-03), pages 2, XP009506567, Retrieved from the Internet [retrieved on 20151231]
"Home", NATURAL STONE PAVERS, 4 January 2014 (2014-01-04), pages 1, XP009506408, Retrieved from the Internet [retrieved on 20151231]
See also references of EP 3377457A4
Attorney, Agent or Firm:
FLINT, Nancy J. (#424, 1856 N. Nob Hill RoadPlantation, Florida, 33322, US)
Download PDF:
Claims:
CLAIMS

What is claimed is:

1 . An environmentally responsible insulated construction block comprising:

a plurality of shredded rubber pieces coated with silica flume, slag cement and cement forming a block having a top surface, a bottom surface substantially parallel to the top surface and 4 side surfaces substantially perpendicular to the top surface and the bottom surface, wherein the block has a depth defined by the distance between the top surface and the bottom surface; and

one or more layers of grout disposed on the exterior of the top surface, the bottom surface or both the top and the bottom surfaces,

wherein the plurality of shredded rubber pieces coated with silica flume, slag cement and cement form an open interior matrix structure.

2. The environmentally responsible insulated construction block of claim 1 , further comprising foam insulation disposed in at least part of the open matrix structure.

3. The environmentally responsible insulated construction block of claim 1 , wherein the block is about 12 inches square.

4. The environmentally responsible insulated construction block of claim 3, wherein the thickness of the block is greater than about 2 inches.

5. The environmentally responsible insulated construction block of claim 4, wherein the thickness of the block is about 4 inches.

6. The environmentally responsible insulated construction block of claim 4, wherein the thickness of the block is between about 2 inches and about 20 inches.

7. The environmentally responsible insulated construction block of claim 2, wherein the block is used in a roofing system.

8. The environmentally responsible insulated construction block of claim 7, wherein the roofing system comprises a low slope roofing system.

9. The environmentally responsible insulated construction block of claim 1 for use in construction of a wall, a deck or a walkway.

10. A method of manufacturing an environmentally responsible insulated construction block comprising:

mixing together substantially dry silica flume, slag cement and cement; thereafter adding shredded rubber pieces to the mixture of substantially dry silica flume, slag cement and cement and mixing until the shredded rubber is substantially completely coated;

thereafter adding water until the substantially dry mix of silica flume, slag cement, cement and shredded rubber pieces is fully wetted;

thereafter pouring the wetted mixture of silica flume, slag cement, cement and shredded rubber pieces into a mold on top of a layer of grout until the mold is substantially full;

fitting each mold with a lid; and

allowing each mold to dry.

1 1 .The method of manufacturing an environmentally responsible insulated construction block of claim 12, wherein the mold dries in ambient air.

Description:
ENVIRONMENTALLY RESPONSIBLE INSULATING CONSTRUCTION BLOCKS

[0001 ] FIELD OF THE INVENTION.

[0002] The invention relates to environmentally responsible insulating construction blocks constructed primarily of recycled materials. The construction blocks comprise shredded rubber tire pieces coated with silica flume, slag cement and cement, which are then mixed with water and formed in a mold. The construction blocks can further comprise insulation foam disposed in the interior open matrix. The environmentally responsible insulating construction blocks provide high insulation as well as strength for applications such as roofing and wall construction, and other applications.

[0003] BACKGROUND.

[0004] In many developed countries the construction and use of buildings is a leading consumer of energy and producer of greenhouse gas emissions. Sustainable architecture seeks to minimize the negative environmental impact of buildings by efficiency and moderation in the use of materials, energy, and development space. Sustainable architecture uses a conscious approach to energy and ecological conservation in the design of the built environment

[0005] Green building (also known as green construction or sustainable building) refers to both a structure and the using of processes that are environmentally responsible and resource-efficient throughout a building's life-cycle, from siting to design, construction, operation, maintenance, renovation, and demolition. Green building rating systems such as BREEAM (United Kingdom), LEED® (United States and Canada), DGNB (Germany), CASBEE (Japan), and VERDEGBCe (Spain) help consumers determine a structure's level of environmental performance. These systems award credits for building features that support green design in categories such as location and maintenance of building site, conservation of water, energy, and building materials, and occupant comfort and health. The number of credits generally determines the level of achievement. Additionally, green building codes and standards, such as the International Code Council's draft International Green Construction Code, are rules created by standards development organizations that establish minimum requirements for elements of green building such as materials or heating and cooling.

[0006] Leadership in Energy and Environmental Design (LEED®) is a set of rating systems for the design, construction, operation, and maintenance of green buildings in the United States and Canada which was developed by the U.S. Green Building Council (USGBC). LEED® certification of a building is recognized across the globe as the premier mark of achievement in green building. LEED®-certified buildings cost less to operate, reducing energy and water bills by as much as 40%. Businesses and organizations across the globe use LEED® to increase the efficiency of their buildings, freeing up valuable resources that can be used to create new jobs, attract and retain top talent, expand operations and invest in emerging technologies.

[0007] The intent of LEED® is to provide a standard certification process that registers buildings constructed with environmental performance, efficiency, and occupant health and well-being as primary goals. Buildings receive points towards varying levels of certification based on the set of categories established by the USGBC. For example, points are awarded with respect to the following features:

• Site development that protects or restores habitat or that maximizes open space;

• Storm water design to minimize impervious surfaces; • Heat island effect that uses alternative surfaces and nonstructural techniques to reduce imperviousness and promote infiltration, reducing pollutant loadings and use of vegetated roofs;

• Water efficiency by use of green roof system without permanent irrigation or that minimizes potable consumption;

• Energy and optimization by establishing the minimum level of energy efficiency for the building and systems; and

• Materials and resources that reuse building materials and products to reduce demand for virgin materials and reduce waste, use of recycled components and use of regional material that has been manufactured and assembled within 500 miles of the building.

[0008] Green roof systems installed on 50% of more of a roof surface virtually guarantees 2 point toward LEED® certification, and can contribute an additional 7+ points. This is almost 20% of the total number of points needed for a building to be LEED®-certified.

[0009] Low slope roofing systems have been developed for use with buildings. Low slope roofing systems commonly include a structural deck made of metal or concrete that is covered with a layer of insulation, and the insulation is then covered with a waterproof membrane. A commercial low slope roof system may use single-ply membranes of prefabricated sheets rolled onto the roof and attached with mechanical fasteners, adhered with chemical adhesives, or held in place with ballast such as gravel, stones, or pavers; built-up roofs consisting of a base sheet, fabric reinforcement layers, and a dark protective surface layer; modified bitumen sheet membranes having one or more layers of plastic or rubber material with reinforcing fabrics, and surfaced with mineral granules or a smooth finish; and spray polyurethane foam roofs constructed by mixing two liquid chemicals together that react and expand to form one solid piece that adheres to the roof then having a protective coating such as metal or tile placed over the polyurethane.

[0010] Low slope roofing insulation became more prevalent during the 1960's and forward as increasingly more buildings became air conditioned and as the cost of energy, both for heating and cooling rose dramatically. Currently insulation levels may exceed R30 as specified by code or because of the building's use and geographic location.

[001 1 ] Insulated panels are known to be used on wall and roof building applications to form part or all of the building envelope. An insulation panel typically has opposing inside and outside surfaces with an insulating foam core adhered between the surfaces. The panel can then be mounted onto support structures to form the wall or roof application in a building.

[0012] Tire recycling or rubber recycling is the process of recycling vehicles' tires that are no longer suitable for use on vehicles due to wear or irreparable damage. These tires are a large and difficult source of waste due to the large volume produced, and the fact they contain a number of components that are ecologically problematic. In the United States alone the Environmental Protection Agency (EPA) estimates that roughly 300 million scrap tires are generated annually. Over 60 million of these tires end up in landfills, ocean, lakes, greatly harming our environment. Local recycling facilities are having a very difficult time dealing with this problem because of the enormous quantities of tires being generated each year and with only so many limited re-use options available to them.

[0013] The same characteristics that make waste tires problematic - cheap availability, bulk, and resilience - also make them attractive targets for recycling. Tires are known to be recycled for use on basketball courts, in hot melt asphalt, for increasing burning value of RDF in incineration plants and new shoe products.

[0014] SUMMARY OF THE INVENTION.

[0015] The invention relates to an environmentally responsible insulating construction block for roofing, wall and other construction applications. The environmentally responsible insulating construction blocks are constructed primarily of recycled materials, specifically, shredded rubber tire pieces coated with silica flume, slag cement and cement, which are then mixed with water and formed in a mold. The construction blocks can further comprise insulation foam disposed in the interior open matrix of the blocks. The construction blocks provide high insulation as well as strength for applications such as roofing and wall construction.

[0016] In one embodiment of the invention, an environmentally responsible insulating construction block is provided for use in roof construction. In this embodiment, the environmentally responsible insulating construction block is provided in side by side relation to a next substantially similar environmentally responsible insulating construction block. In one embodiment, a plurality of the environmentally responsible insulating construction blocks are tapered to create a "slope to drain" roofing system.

[0017] In one embodiment of the invention, an environmentally responsible insulating construction block is provided for use in wall construction. In this embodiment, the environmentally responsible insulating construction block is provided in side by side relation to a next substantially similar environmentally responsible insulating construction block. [0018] In one embodiment of the invention, an environmentally responsible insulating construction block is provided for use in wall construction. In this embodiment, the environmentally responsible insulating construction block is provided in stacking relation to a next substantially similar environmentally responsible insulating construction block.

[0019] In one embodiment of the invention, an environmentally responsible insulating construction block is provided for use in decking construction. In this embodiment, the environmentally responsible insulating construction block is provided in side by side relation to a next substantially similar environmentally responsible insulating construction block.

[0020] In one embodiment of the invention, an environmentally responsible construction block is provided for use in walkway construction. In this embodiment, the environmentally responsible construction block is provided in side by side relation to a next substantially similar environmentally responsible insulating construction block.

[0021 ] The environmentally responsible insulating construction block comprises a plurality of shredded rubber pieces dry mixed with silica flume, slag cement and cement until the shredded rubber tire pieces are coated. Water is then added to the dry mixture, and thereafter the wetted mixture is placed in a mold on top of a layer of grout whereupon it dries into an environmentally responsible insulating construction block. The dried environmentally responsible insulating construction block comprises an interior open matrix.

[0022] In one embodiment of the invention, an insulating foam is disposed into the open matrix of the environmentally responsible insulating construction block. [0023] In one embodiment of the invention, the environmentally responsible insulating construction block comprises a bottom surface, a top surface comprising the grout layer and 4 side surfaces substantially perpendicular to the top surface and the bottom surface, wherein the environmentally responsible insulating construction block has a thickness defined by the distance between the top surface and the bottom surface.

[0024] In one embodiment of the invention, the environmentally responsible insulating construction block is utilized in a green roofing system. The bottom surface of the environmentally responsible insulating construction block is placed on a layer of high strength self-setting grout that binds the environmentally responsible insulating construction block to a roof deck. A layer of adhesive, or glue, is placed on the top grout surface of the environmentally responsible insulating construction block which membrane roofing systems adhere.

[0025] In one embodiment, the environmentally responsible insulating construction block is utilized in construction of walls or other vertical constructions; decking; or walkways.

[0026] BRIEF DESCRIPTION OF THE DRAWINGS.

[0027] The invention will now be described, by way of example, with reference to the accompanying drawings, in which like numerals refer to like elements.

[0028] FIG. 1 depicts a roofing system comprising an environmentally responsible insulating construction block according to one embodiment of the invention.

[0029] FIGS. 2A-2G depict the steps of manufacturing the environmentally responsible insulating construction block according to one embodiment of the invention. [0030] FIG. 3 depicts an environmentally responsible insulating construction block having insulating foam disposed in the open matrix according to one embodiment of the invention.

[0031 ] DETAILED DESCRIPTION OF THE INVENTION.

[0032] The invention relates to an environmentally responsible insulating construction block for roofing, wall and other construction applications. The environmentally responsible insulating construction blocks are constructed primarily of recycled materials, specifically, shredded rubber pieces coated with silica flume, slag cement and cement, which are then mixed with water and formed in a mold on a layer of grout to form a block having an open matrix. The construction blocks can further comprise insulation foam disposed in the interior open matrix. The construction blocks provide high insulation as well as strength.

[0033] In one embodiment of the invention, an environmentally responsible insulating construction block is provided for use in roof construction. In this embodiment, the environmentally responsible insulating construction block is provided in side by side relation to a next substantially similar environmentally responsible insulating construction block.

[0034] In one embodiment of the invention, an environmentally responsible insulating construction block is provided for use in roofing construction. In this embodiment, the environmentally responsible insulating construction block is provided in side by side relation to a next substantially similar environmentally responsible insulating construction block. In this embodiment, a plurality of the environmentally responsible insulating construction blocks are tapered to create a "slope to drain" roofing system. [0035] In one embodiment of the invention, an environmentally responsible insulating construction block is provided for use in wall construction. In this embodiment, the environmentally responsible insulating construction block is provided in stacking relation to a next substantially similar environmentally responsible insulating construction block wherein a layer of grout is placed between adjacent environmentally responsible insulating construction blocks.

[0036] In one embodiment of the invention, an environmentally responsible insulating construction block is provided for use in decking construction. In this embodiment, the environmentally responsible insulating construction block is provided in side by side relation to a next substantially similar environmentally responsible insulating construction block.

[0037] In one embodiment of the invention, an environmentally responsible construction block is provided for use in walkway construction. In this embodiment, the environmentally responsible construction block is provided in side by side relation to a next substantially similar environmentally responsible insulating construction block.

[0038] In one embodiment of the invention, an insulating foam is disposed into the open matrix of the environmentally responsible insulating construction block.

[0039] In one embodiment of the invention, the environmentally responsible insulating construction block comprises a bottom surface, a top surface substantially parallel to the bottom surface comprising a grout layer and 4 side surfaces substantially perpendicular to the top surface and the bottom surface, wherein the environmentally responsible insulating construction block has a thickness defined by the distance between the top surface and the bottom surface. [0040] In one embodiment, the shredded rubber pieces comprise shredded tires. In one embodiment, the shredded rubber pieces are approximately 2 inches nominal thickness. In one embodiment, the shredded rubber pieces have a thickness greater than approximately 2 inches. In one embodiment, the shredded rubber pieces have a thickness greater than approximately 2 inches and less than approximately 20 inches.

[0041 ] In one embodiment of the invention, the environmentally responsible insulating construction block is utilized in a green roofing system. The bottom surface of the environmentally responsible insulating construction block is placed on a layer of high strength self-setting grout that binds the environmentally responsible insulating construction block to a roof deck. A layer of adhesive or glue is placed on the top surface of the environmentally responsible insulating construction block to which current membrane roofing systems adhere.

[0042] In one embodiment, the environmentally responsible insulating construction block is utilized in construction of walls or other vertical constructions; decking; or walkways.

[0043] In one embodiment of the invention, the environmentally responsible insulating construction block has a thickness (measured from the bottom surface to the top surface) ranging from around 2 inches to around 20 inches, with length and width (measured along the side surfaces) of around 12 inches square. Other dimensions of the environmentally responsible insulating construction block may be constructed in accordance with the principles of the invention and these preceding dimensions are listed as examples only and are not intended in any way to limit the invention.

[0044] Turning to the figures, FIG. 1 depicts one embodiment of a roofing system 100 comprising environmentally responsible insulated construction blocks 1 10. The roofing system 100 comprises a low slope roof structure 120 that includes a metal or concrete deck 130 and a plurality of environmentally responsible insulated construction blocks 1 10. Environmentally responsible insulated construction blocks 1 10 are attached to the metal or concrete deck 130 using high strength self-setting grout 140, and a waterproof membrane 150 is disposed on an adhesive or glue layer 125 that is disposed on the top surfaces 1 15 of the environmentally responsible insulated construction blocks 1 10.

[0045] In one embodiment, waterproof membrane 150 comprises any membrane known today or later developed for roofing or other construction purposes. Waterproof membrane 150 may vary according to the use and the climate of the construction.

[0046] In one embodiment, the roofing system meets building codes designed to withstand severe weather conditions, such as strong winds. 101 .4.2 Florida Building Code (FBC), for example, applies to "the construction, erection, alteration, modification, repair, equipment, use and occupancy, location, maintenance, removal and demolition of every public and private building, structure . . ." and sets forth requirements for buildings to withstand wind forces resulting from design wind speeds. In Broward County, Florida, buildings must withstand wind forces of 140 mph, and in Miami-Dade County, Florida, buildings must withstand wind forces of 146 mph. Other standards exist, for example ASCE (American Society of Civil Engineers)-7 and Florida Statute 553.844 setting forth Building Construction Standards titled "Windstorm loss mitigation; requirements for roofs and opening protection." These standards may also apply to roof replacement.

[0047] FIGS. 2A-2G depict the steps of manufacturing the environmentally responsible insulating construction block according to one embodiment of the invention.

[0048] In FIG. 2A, a dry mixture is made from silica flume, slag cement and cement. [0049] In FIG. 2B, shredded tire pieces are added to the dry mixture and mixed until coated.

[0050] In FIG. 2C, water is added to the dry mix until the dry mix is fully wetted.

[0051 ] In FIG. 2D, molds are prepared and a layer of grout is added to the bottom of each mold.

[0052] In FIG. 2E, the wetted mix is added into each mold until full.

[0053] In FIG. 2F, each mold is fitted with a lid and left to sit in ambient air until dry.

[0054] In FIG. 2G, the dried environmentally responsible insulating construction blocks are removed from the molds and are ready for use.

[0055] FIG. 3 depicts an environmentally responsible insulating construction block 300 having insulating foam 310 disposed in the interior open matrix according to one embodiment of the invention. Environmentally responsible insulating construction block 300 comprises a top surface 301 having a grout layer 315; a bottom surface 302; and four side walls 303. Shredded rubber tire pieces 305 that have been coated with silica flume, slag cement and cement and then mixed with water and dried to form an open matrix in the interior of environmentally responsible insulating construction block 300. In this embodiment, insulating foam 320 is disposed in some or all of the interior open matrix of environmentally responsible insulating construction block 300.

[0056] EXAMPLE.

[0057] The following example illustrates the manufacture and characteristics of the environmentally responsible insulated construction block in further detail. This example is exemplary only and in no way limits or is intended to limit the scope of this invention.

[0058] Manufacture of an Environmentally Responsible Insulated Construction Block. [0059] 1 gallon of silica flume, 1 gallon of slag cement and 1 .5 gallons of cement were mixed together for at least 2 minutes. Seventy-five (75) lbs. of shredded tire pieces were added to the mix, and the resulting mixture was mixed for another five (5) minutes. Thereafter, 2 gallons of water were added to wet the dry mixture. When the mixture was fully wetted, the mixture was poured into molds sized 12 inches by 12 inches by 4 inches deep to which ½ inch of grout had previously been added. The molds were filled and a lid closed over the mold and left to dry for 5 days at room temperature in the ambient environment. Once the mixture was dry in each mold, the resulting environmentally responsible insulated construction blocks were removed and were ready for use in construction.

[0060] The environmentally responsible insulated construction blocks made according to the process of Para. [0059] were tested for uplift pressure resistance. Testing was conducted according to Testing Application Standard (TAS) 1 14-95 Appendix "D" of the International Code Council® using a 5000 lb. capacity force Chatillon tester using a 12"x12" shredded tire mix with top and bottom topping of 1 " mortar mix directly to a concrete deck according to Miami Dade County uplift protocol. The fail pressure was 937.5 psf which far exceeds the 45 psf minimum Miami-Dade County, Florida requirements.

[0061 ] In the foregoing description, the invention has been described with reference to specific exemplary embodiments thereof. It will be apparent to those skilled in the art that a person understanding this invention may conceive of changes or other embodiments or variations, which utilize the principles of this invention without departing from the broader spirit and scope of the invention. The specification and drawings are, therefore, to be regarded in an illustrative rather than a restrictive sense.