Building block, building block mold, and method for forming building block
First Claim
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1. A building block, comprising:
- a plurality of opposing spaced apart outer walls, each outer wall having an outer wall portion exhibiting a first density that surrounds an interior portion having a second density that is less than the first density;
a plurality of stalks of agricultural by-products that are bonded together with an added binder that includes an isocyanate, a reaction product involving a reaction with an isocyanate, or both in addition to any naturally occurring binder of the stalks;
wherein the plurality of stalks are randomly oriented, and have an average length of greater than about 3 cm;
wherein the ratio by weight of the stalks to the added binder is greater than about 10;
1,wherein a progressive density gradient exists from the outer wall portion toward the interior portion.
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Abstract
The present invention provides an improved building block formed of recycled straw stalks, a mold for forming the block, and a method of forming the block. The improved block provides a moisture and pest resistant building block having high dimensional tolerances and being capable of long term use without structural degradation.
39 Citations
19 Claims
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1. A building block, comprising:
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a plurality of opposing spaced apart outer walls, each outer wall having an outer wall portion exhibiting a first density that surrounds an interior portion having a second density that is less than the first density; a plurality of stalks of agricultural by-products that are bonded together with an added binder that includes an isocyanate, a reaction product involving a reaction with an isocyanate, or both in addition to any naturally occurring binder of the stalks; wherein the plurality of stalks are randomly oriented, and have an average length of greater than about 3 cm; wherein the ratio by weight of the stalks to the added binder is greater than about 10;
1,wherein a progressive density gradient exists from the outer wall portion toward the interior portion. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A building block, comprising:
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a plurality of opposing spaced apart outer walls, each outer wall having an outer wall portion exhibiting a first density that surrounds an interior portion having a second density that is less than the first density; a plurality of stalks of agricultural by-products that are bonded together with a synthetically made resin binder in addition to any naturally occurring binder of the stalks; wherein the plurality of stalks are randomly oriented, and have an average length of greater than about 3 cm; wherein the ratio by weight of the stalks to the added binder is greater than about 10;
1,wherein a progressive density gradient exists from the outer wall portion toward the interior portion. - View Dependent Claims (15, 16, 17)
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18. A building block, comprising:
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a plurality of opposing spaced apart outer walls, each outer wall having an outer wall portion exhibiting a first density that surrounds an interior portion having a second density that is less than the first density; a plurality of stalks of agricultural by-products that are bonded together with a synthetically made resin binder in addition to any naturally occurring binder of the stalks; wherein the plurality of stalks are randomly oriented, and have an average length of greater than about 6 cm; wherein the ratio by weight of the stalks to the added binder is greater than about 10;
1,wherein a progressive density gradient exists from the outer wall portion toward the interior portion. - View Dependent Claims (19)
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Specification