Culm blocks

• US 20030208982A1
• Filed: 05/10/2002
• Published: 11/13/2003
• Est. Priority Date: 05/10/2002
• Status: Active Grant

• Current Assignee: Oryzatech, Inc.
• Original Assignee: Oryzatech, Inc.
• Inventors: Priest, Doug C., Ruskey, John A. III, Korman, Benjamin Z.
• Granted Patent: US 6,951,080 B2
• Time in Patent Office: Days
• US Class Current: 52/596
• CPC Class Codes: E04B 1/3555 Constructions using straw bales
• CPC Class Codes: E04B 2/02 built-up from layers of building elements

Abstract

A culm block and a method of manufacture are disclosed. The culm block comprises a plurality of straw stalks that are “vertically aligned”, i.e., perpendicular to the ground when the block is laid flat. The straw is treated with a moisture inhibitor and/or a binder. Throughholes, which may have tubes associated therewith, are formed into the top and bottom walls of the culm block. A lath or external strapping sleeve is wrapped about the front, rear, and side walls of the block for added structural support. The method of manufacture may include sorting the stalks according to length, checking the stalks for moisture content, and drying the stalks depending upon their moisture content prior to compression and formation.

Claims

1. A building block comprising:

a plurality of adjacent stalks substantially aligned parallel to one another and formed to define a block for building, the strands having a predetermined moisture content;

a binder disposed on or integrated into the strands for maintaining the shape of the block; and

a moisture inhibitor disposed on or integrated into the strands for maintaining the moisture content.

2. The building block of claim 1 wherein the block has a top wall and an opposing bottom wall defining at least one throughhole.

3. The building block of claim 2 further comprising tubing inserted in the throughhole.

4. The building block of claim 1 wherein the moisture content is approximately 14% or less.

5. The building block of claim 1 wherein the block weighs approximately 40 lbs. or less.

6. The building block of claim 1 wherein the block is approximately 24″

long by 12″

wide by 12″

high.

7. The building block of claim 1 wherein the block has a planar bottom wall for lying against a ground surface, and wherein the stalks are aligned substantially orthogonal to the bottom wall.

8. The building block of claim 1 wherein the moisture inhibitor and the binder are the same.

9. The building block of claim 1 wherein the moisture inhibitor is borax.

10. The building block of claim 1 wherein the stalks are rice straw.

11. The building block of claim 1 further comprising a lath substantially wrapped about the block.

12. The building block of claim 1 wherein the stalks are of substantially the same length.

13. A building block comprising:

a plurality of adjacent stalks substantially aligned parallel to one another and formed to define a rectangular block for building;

wherein the length of the block is defined by a bottom wall lying in a first plane, the width of the block is defined by a side wall lying in a second plane orthogonal to the first plane, and the height of the block is defined by a front wall lying in a third plane substantially orthogonal to both the first and second planes;

wherein the stalks are aligned substantially orthogonal to the bottom wall, whereby the bottom wall of the block may be laid flat against a ground surface and the stalks are vertically aligned to the ground surface in the third plane.

14. The building block of claim 13 further comprising a moisture inhibitor disposed on or integrated into the stalks.

15. The building block of claim 13 further comprising a binder disposed on or integrated into the stalks.

16. The building block of claim 13 further comprising a moisture inhibitor and a binder disposed on or integrated into the stalks, wherein the moisture inhibitor and the binder comprise borax.

17. The building block of claim 13 wherein the block has a top wall opposing the bottom wall and a hole defined by the top wall and the bottom wall.

18. The building block of claim 17 further comprising tubing inserted in the hole.

19. The building block of claim 13 wherein the stalks have a predetermined moisture content of approximately 14% or less.

20. The building block of claim 13 wherein the stalks are rice straw.

21. The building block of claim 13 further comprising a lath substantially wrapped about the block.

22. The building block of claim 13 wherein the stalks are of substantially the same length.

23. A building block comprising:

a plurality of adjacent stalks substantially aligned parallel to one another to form a rectangular block having a top wall and an opposing bottom wall that define the length of the block, a front wall and an opposing rear wall, and a first side wall and an opposing second side wall; and

a lath disposed about the front, rear, and first and second side walls;

wherein the stalks are aligned substantially orthogonal to the top and bottom walls and substantially parallel to the front, rear, and first and second side walls.

24. The building block of claim 23 further comprising a moisture inhibitor and a binder disposed on or integrated into the stalks.

25. The building block of claim 23 wherein the top and bottom walls define a throughhole.

26. The building block of claim 23 wherein the stalks have a predetermined moisture content of approximately 14% or less.

27. The building block of claim 23 wherein the stalks are rice straw.

28. The building block of claim 23 wherein the stalks are of substantially the same length.

29. A method of forming a building block comprising:

aligning a plurality of stalks substantially parallel to one another;

sorting the stalks according to length;

compressing together aligned stalks of substantially similar length to form a block for building.

30. The method of forming a building block according to claim 29 further comprising checking the stalks for moisture content, and drying the stalks depending upon moisture content.

31. The method of forming a building block according to claim 30 wherein the stalks are dried to a moisture content of 14% or less.

32. The method of forming a building block according to claim 29 further comprising treating the stalks with a binder and a moisture inhibitor.

33. The method of forming a building block according to claim 29 wherein the stalks are aligned substantially parallel to one another to form a rectangular block having a top wall and an opposing bottom wall that define the length of the block, and wherein the stalks are aligned substantially orthogonal to the top and bottom walls.

34. The method of forming a building block according to claim 29 further comprising drilling a hole through the block.

35. The method of forming a building block according to claim 34 wherein the hole is aligned substantially parallel to the alignment of the stalks in the formed block.

36. The method of forming a building block according to claim 35 wherein the stalks are rice straw.

37. A method of forming a building block comprising:

aligning a plurality of stalks substantially parallel to one another;

checking the stalks for moisture content;

drying the stalks depending upon moisture content; and

compressing together aligned stalks to form a block for building.

38. The method of forming a building block according to claim 37 further comprising sorting the stalks according to length.

39. The method of forming a building block according to claim 37 wherein the stalks are dried to a moisture content of 14% or less.

40. The method of forming a building block according to claim 37 further comprising treating the stalks with a binder and a moisture inhibitor.

41. The method of forming a building block according to claim 37 wherein the stalks are aligned substantially parallel to one another to form a rectangular block having a top wall and an opposing bottom wall that define the length of the block, and wherein the stalks are aligned substantially orthogonal to the top and bottom walls.

42. The method of forming a building block according to claim 41 wherein the stalks are rice straw.

43. A method of forming a building block comprising:

treating a plurality of stalks with a binder;

treating the stalks with a moisture inhibitor; and

compressing together the treated stalks to define a block for building.

44. The method of forming a building block according to claim 43 further comprising sorting the stalks according to length.

45. The method of forming a building block according to claim 43 further comprising checking the stalks for moisture content, and drying the stalks depending upon moisture content.

46. The method of forming a building block according to claim 45 wherein the stalks are dried to a moisture content of 14% or less.

47. The method of forming a building block according to claim 43 further comprising aligning the stalks substantially parallel to one another.

48. The method of forming a building block according to claim 47 wherein the stalks are aligned substantially parallel to one another to form a rectangular block having a top wall and an opposing bottom wall that define the length of the block, and wherein the stalks are aligned substantially orthogonal to the top and bottom walls.

49. The method of forming a building block according to claim 43 wherein the stalks are rice straw.