阅读说明：本技术 环保可靠的隔热建筑块和结构 (Environment-friendly and reliable heat insulation building block and structure ) 是由 R·斯普林 于 2018-05-16 设计创作，主要内容包括：公开了主要由回收材料构成的环保可靠的隔热建筑块和结构。环保建筑块和结构包括涂覆有硅灰、矿渣水泥和水泥的切碎的橡胶轮胎碎片，然后与水混合并在模具中成型。可以在环保可靠的隔热建筑块的一侧上设置一层灌浆或防火材料。环保可靠的隔热建筑块可为例如绿化屋顶、壁结构和绿化屋顶铺面等应用提供高隔热性和强度。可以通过以下方式构建环保结构：将涂覆过的切碎的橡胶轮胎碎片浇注模具中以形成壁，然后浇注一层涂覆过的切碎的橡胶轮胎碎片作为屋顶铺面，从而在整体式浇注中创建自支撑结构。(Environmentally friendly, reliable insulated building blocks and structures composed primarily of recycled materials are disclosed. Environmentally friendly building blocks and structures comprise shredded rubber tire chips coated with silica fume, slag cement and cement, then mixed with water and shaped in a mold. A layer of grouting or fire-resistant material may be provided on one side of the environmentally-friendly and reliable insulating building block. Environmentally sound insulating building blocks can provide high thermal insulation and strength for applications such as green roofs, wall structures, and green roof decking. The environmentally friendly structure may be constructed by: the coated shredded rubber tire shreds are cast into a mold to form a wall, and then a layer of the coated shredded rubber tire shreds is cast as a roof deck, creating a self-supporting structure in a unitary casting.)

1. An environmentally sound, insulated building block for greenery paving applications, comprising:

a first layer of a plurality of shredded rubber tire fragments coated with silica fume, slag cement and cement, and a second layer of a plurality of pieces of a fire-resistant material coated with silica fume, slag cement and cement,

forming a block having a top surface, a bottom surface substantially parallel to the top surface, and four side surfaces substantially perpendicular to the top and bottom surfaces, wherein the block has a depth defined by the distance between the top and bottom surfaces;

wherein the shredded rubber tire pieces range in size from about 1/2 inches to 2 inches,

wherein the shredded rubber tire pieces account for at least 50% by weight of the shredded rubber tire pieces, silica fume, slag cement and cement,

wherein the environmentally responsible insulated building block forms an open matrix structure allowing liquid to pass substantially freely through the environmentally responsible insulated building block.

2. The environmentally friendly, reliable insulated building block of claim 1, wherein the second layer is about 1 inch thick.

3. The environmentally friendly, reliable, insulated building block of claim 1, wherein the block is about 12 inches square.

4. The environmentally friendly, reliable, insulated building block of claim 3, wherein the building block has a thickness greater than about 2 inches.

5. The environmentally friendly, reliable, insulated building block of claim 4, wherein the block has a thickness of about 4 inches.

6. The environmentally friendly, reliable, insulated building block of claim 4, wherein the shredded rubber tire has a size in a range of between about 1 inch and 2 inches.

7. The environmentally friendly, reliable, insulated building block of claim 2, wherein the block is used in an afforested paving system.

8. The environmentally safe, insulated building block of claim 1, wherein the fire-blocking material comprises expanded slate.

9. A method of making an environmentally sound, thermally insulating building block for green roof applications, comprising:

mixing a first mixture of substantially dry silica fume, slag cement and cement;

thereafter adding shredded rubber tire pieces to the first mixture and mixing until the shredded rubber is substantially completely coated;

then adding water until the mixture of silica fume, slag cement, cement and shredded rubber tire chips is completely wetted;

mixing a second mixture of substantially dry silica fume, slag cement and cement;

then adding the shredded pieces of fire-protecting material to the second mixture and mixing until the pieces of fire-protecting material are substantially completely coated;

adding water until the mixture of the silica fume, the slag cement, the cement and the fragments of the fireproof material is completely wetted;

then pouring the wetted fire-proof material mixture layer at the bottom of the mould;

the wetted shredded rubber mixture is then poured into the mold on top of the layer of wetted fireproofing mixture until the mold is substantially full;

covering each mould with a cover; and

each mold was allowed to dry.

10. The method of claim 9, wherein the fire-blocking material comprises expanded slate.

11. The method of making an environmentally sound and insulated building block of claim 9, wherein the mold is dried in ambient air.

12. The method of making an environmentally sound insulated building block of claim 9, wherein the shredded rubber tire chips range in size between about 1/2 inches and 2 inches.

13. A green roof decking comprising:

a membrane roof system comprising an insulation layer adhered to a substrate of a roof structure, and a waterproofing membrane layer adhered to the insulation layer remote from the roof substrate; and

an environmentally friendly and reliable insulating building block attached to a waterproof membrane layer of a membrane roof system,

wherein, the environment-friendly and reliable heat insulation building block comprises:

a first layer coated with a plurality of shredded rubber tire fragments of silica fume, slag cement and cement, a second layer coated with a plurality of fragments of fire-resistant material of silica fume, slag cement and cement,

forming a block having a top surface, a bottom surface substantially parallel to the top surface, and four side surfaces substantially perpendicular to the top and bottom surfaces, wherein the block has a depth defined by the distance between the top and bottom surfaces;

wherein the shredded rubber tire pieces range in size from about 1/2 inches to about 2 inches,

wherein the shredded rubber tire pieces account for at least 50% by weight of the shredded rubber tire pieces, silica fume, slag cement and cement,

wherein the environmentally sound insulating building block forms an open matrix structure allowing liquid to freely pass through the environmentally sound insulating building block.

14. The green roof covering of claim 13, wherein the fire-blocking material comprises expanded slate.

15. An environmentally friendly thermal insulation structure comprising:

a foundation, a plurality of outer walls, and a roof,

wherein one or more of the outer walls are prepared by:

preparing a mould;

placing the mold on a foundation;

placing a layer of grouting on the bottom of the mold on the foundation;

pouring a mixture comprising shredded rubber tire chips coated with silica fume, slag cement and cement in a mold;

covering the top surface of the poured mixture with a cover and attaching it to a metal rod;

applying pressure on the cover to compress the mixture in the mold;

drying the mixture in the mold; and

the covering and the mould are then removed,

wherein the roof is prepared by the steps of:

preparing a roof structure on top of the plurality of outer walls;

placing a formwork around the outer edge of the roof structure;

attaching a plurality of metal rods to the roof structure to extend vertically upward from the roof structure;

pouring a mixture comprising shredded rubber tire chips coated with silica fume, slag cement and cement on a roof structure;

covering the top surface of the mixture poured onto the roof structure with a covering and attaching it to the metal rods;

applying pressure on the covering to compress the mixture cast on the roof structure;

drying the mixture cast on the roof structure;

removing the cover and the template; and

the dried mixture on the roof structure is then covered with a protective layer,

wherein the shredded rubber tire pieces in the mixture range in size from about 1/2 inches to 2 inches,

wherein the shredded rubber tire pieces account for at least 50% by weight of the mixture of shredded rubber tire pieces, silica fume, slag cement and cement.

16. The environmentally friendly insulation structure of claim 16, wherein each outer wall is about twelve inches thick.

17. The environmentally friendly insulating structure of claim 16, wherein the covering comprises plywood.

18. The environmentally friendly insulation structure of claim 16, wherein the protective covering comprises one of stucco, roofing paint, or a combination thereof.

19. The environmentally friendly insulating structure of claim 16, wherein the foundation comprises a ground surface.

20. An environmentally-friendly, reliable, insulated building block for green roof applications, comprising:

a layer of a plurality of shredded rubber tyre fragments coated with silica fume, slag cement and cement,

forming a block having a top surface, a bottom surface substantially parallel to the top surface, and four side surfaces substantially perpendicular to the top and bottom surfaces, wherein the block has a depth defined by the distance between the top and bottom surfaces;

wherein the shredded rubber tire pieces range in size from about 1/2 inches to 2 inches,

wherein the shredded rubber tire pieces account for at least 50% by weight of the shredded rubber tire pieces, silica fume, slag cement and cement,

wherein the environmentally-friendly and reliable heat-insulating building blocks form an open matrix structure.

Technical Field

The present invention relates to environmentally friendly, reliable, insulated building blocks and structures constructed primarily of recycled materials. Environmentally sound insulating building blocks and structures include shredded rubber tire chips coated with silica fume, slag cement and cement, which are then mixed with water and formed in a mold. In one embodiment, a grout layer is provided on one side of the environmentally sound insulating building block for use in a roofing system. In one embodiment, a permeable layer of fire-blocking material is disposed on one side of the environmentally sound insulating building block. The environment-friendly and reliable heat insulation building block can provide high heat insulation property and strength for greening roof platforms and other applications. The environmentally friendly structure may be constructed by: the entire structure is formed in one integral casting by casting the coated shredded rubber tire pieces in a mold to form the walls and then casting a layer of the coated shredded rubber tire pieces as a roofing shingle.

Background

In many developed countries, the construction and use of buildings are major consumers of energy and producers of greenhouse gas emissions. Sustainable construction strives to minimize the negative impact of buildings on the environment by making efficient and cost-effective use of materials, energy and development space. The sustainable building adopts a conscious method to carry out energy and ecological protection in the design of building environment.

Green buildings (also referred to as green buildings or sustainable buildings) refer to the use of environmentally friendly and resource efficient structures and processes throughout the life cycle of a building, from siting to design, construction, operation, maintenance, finishing and demolition. BREEAM (British),

Green building rating systems (us and canada), DGNB (germany), CASBEE (japan) and verdeggbce (spain) can help consumers determine the environmental performance level of a building. This is achieved byThese systems gain honor by supporting green design building functions, these building categories include location and maintenance of building sites, conservation of water, energy and building materials, and comfort and health of occupants. The amount of honor generally determines the level of achievement. Furthermore, green building codes and standards (e.g., the international green building code draft of the international code committee) are rules created by standards-making organizations that specify minimum requirements for green building elements (e.g., materials or heating and cooling).

Leadership in Energy and Environmental Design

Is a set of rating systems developed by the United States Green Building Council (USGBC) for the design, construction, operation and maintenance of united states and canadian green buildings. Of buildings

Certification is a globally recognized primary sign of green building success.

Certified buildings operate at lower costs, reducing energy and water costs by as much as 40%. Used by enterprises and organizations all over the world

The efficiency of the building is improved, precious resources are released, and the resources can be used for creating new working opportunities, attracting and retaining top talents, expanding operation and investing in emerging technologies.

The purpose of (a) is to provide a standard authentication process that registers buildings with environmental performance, efficiency, and the health and well-being of the occupants as major targets. The building obtains scores that point to different levels of authentication from the set of categories established by the USGBC. For example, points are awarded for the following features:

field development, which protects or restores habitat or maximizes open space;

rain design, which minimizes impervious surfaces;

heat island effect using alternative surface and non-structural techniques to reduce imperviousness and promote penetration, reduce pollutant load and use of vegetation roofs;

water conservation by using a green roof system without permanent irrigation or minimizing drinking water consumption;

energy and optimization is achieved by determining the lowest energy efficiency level of the building and system; and

materials and resources that reuse building materials and products to reduce demand for raw materials and reduce waste; using reusable components and using regional materials that are manufactured and assembled within 500 miles of the building.

A greening roof system installed over 50% of the roof surface is actually guaranteed

Authenticate 2 points and may contribute 7+ points additionally. This is almost achieved

20% of the total required points for certified buildings.

Low-grade roof systems for buildings have been developed. Low-grade roof systems typically include structural decking made of metal or concrete, covered with an insulating layer, and then covered with a water-resistant film. Commercial low-grade roof systems may use: single-layer membranes of prefabricated panels, which are rolled up on the roof and connected by mechanical fasteners, glued with chemical adhesives or fixed in position with ballast such as crushed stones, stones or tiles; a composite roof comprised of a base plate, a fabric reinforcing layer, and a dark colored protective surface layer; a modified bituminous laminar film having one or more layers of plastic or rubber material with reinforcing fabric, the surface of which is coated with mineral particles or a smooth facing; and polyurethane foam roofing is sprayed by mixing two liquid chemicals together, allowing them to react and expand to form a solid block which adheres to the roof and is then covered with a protective layer such as metal or ceramic tile.

In the 1960 s and beyond, low-grade roof insulation became more and more prevalent, with the energy costs of air conditioning and heating and cooling rising dramatically as more and more buildings were being equipped. The current insulation rating may exceed the specification for R30 or vary depending on the use and geographic location of the building.

Insulating panels are known for use in wall and roof construction applications to form part or all of a building envelope. Insulation panels typically have opposite inner and outer surfaces with an insulating foam core adhered between the surfaces. The panels may then be mounted to a support structure to form a wall or roof application in a building.

In the luxury real estate market, purchasers in high-rise buildings seek residential space on the roof of the building to provide convenience such as gardens and swimming pools. A green or movable roof is a roof of a building which is partially or completely covered with vegetation and growth media and covered with a waterproof membrane. It may also include other layers such as root barriers as well as drains and irrigation systems.

One drawback of green roofs is the additional mass of soil and retained water, which puts a great strain on the structural support of the building. Certain types of green roofs also have higher structural standards, such as in earthquake and hurricane prone areas of the world. Certain existing buildings cannot be retrofitted with certain types of green roofs because the weight load of the base and vegetation exceed the allowable static loads. For example, the weight of green roofs has resulted in the collapse of large stadium roofs in hong kong in 2016.

One known method of providing a high-rise roof greening space is through the use of inverted roof membrane modules (IRMAs), also known as protective film Roof Systems (PMRs) or modular roof (BURs) systems. In IMRA, a waterproof membrane is typically adhered to the roof structure of a building, and then a protective moisture-resistant insulating layer is laid to protect the membrane from atmospheric degradation, such as sun exposure, wind and rain, and human traffic. A mesh layer may be laid to filter debris and the insulation layer compacted with ballast (e.g., crushed wood or brick). The camber or slope of the roof is formed during construction to deliver water to the roof drain. An example of an IRMA is shown in fig. 1.

Tire recycling or rubber recycling refers to the recycling process of vehicle tires that are no longer suitable for use on a vehicle due to wear or irreparable damage. These tires are a large and difficult waste source due to the large production volumes and in fact they contain many ecologically problematic components. In the united states alone, the Environmental Protection Agency (EPA) estimates that about 3 million used tires are produced each year. Over 6000 million of these tires are eventually placed in landfills, oceans, lakes, and severely harming our environment. Local recycling facilities have difficulty solving this problem because of the large number of tires produced each year and the limited number of reuse options available.

The same features that make scrap tires problematic-inexpensive availability, bulk and elasticity-also make it an attractive recycling target. It is well known that tires can be recycled for use in basketball courts, hot melt asphalt, to enhance the burning value of RDF in incinerators and new footwear products.

Disclosure of Invention

The present invention relates to environmentally responsible and reliable insulating building blocks for greening roof and decking applications and environmentally friendly structures. The environmentally friendly building block can provide high thermal insulation and strength for applications such as greening roofs and paved buildings. In addition, the green structure can be built in one monolithic casting.

In one embodiment of the invention, an environmentally sound insulating building block is adhered to a waterproofing membrane that is adhered to a top layer of an insulating layer of a roof system that is adhered to a roof base of a building to provide a green roof application.

In one embodiment, environmentally responsible, reliable insulation building blocks are positioned side-by-side with similar environmentally responsible, insulation building blocks and adhered to a roof substrate to provide an insulation layer for a membrane roof system. The method includes adhering a waterproofing membrane to the top of an environmentally sound insulating building block, and then adhering the environmentally sound insulating building block to the waterproofing membrane for use as a green roof application.

In one embodiment, an environmentally sound insulating building block is laminated with a top layer of permeable fire-blocking material for use as a landscaping decking application.

In one embodiment, a plurality of environmentally sound insulating building blocks are adhered to a waterproofing membrane adhered to a top layer of an insulating layer of a roof system adhered to a roof substrate of a building to provide a green roof application. A second layer of environmentally responsible insulating building blocks having a top layer of permeable fire-blocking material is adhered to the top layer of a green roofing application for use as a green decking application. In one embodiment, the top of the environmentally sound insulating building blocks forming the green roof application are tapered to create a "tilt to drain" roof system. The bottom surface of the environmentally responsible insulated building block for green decking tapers to correspond to the top portion of the environmentally responsible insulated building block for green roofing applications. The inclination of the top and bottom of the environmentally sound insulating building block prevents liquid from flowing directly to the roof drain. The permeability of environmentally sound insulating building blocks for green decking allows water to pass through and be directed to the roof drain.

An environmentally sound insulating building block for greenery paving applications includes a plurality of shredded rubber tire pieces dry mixed with silica fume, slag cement and cement until the shredded rubber tire pieces are coated. Water is then added to the dried coated shredded rubber mixture. A layer of permeable fire-blocking material is placed in a mold, and a wetted shredded rubber tire compound is placed in the mold on top of the layer of permeable fire-blocking material and then dried into an environmentally sound insulating building block for greendecking applications. A dry, environmentally sound, insulated building block for greening pavements includes an open-ended substrate from the top through which a liquid (e.g., water) can freely pass.

In one embodiment, the permeable fire-blocking material comprises expanded slate.

An environmentally sound, thermally insulating building block for green roofing applications includes a plurality of shredded rubber tire chips dry-blended with silica fume, slag cement, and cement until the shredded rubber tires are coated. Water is then added to the dried coated shredded rubber mixture. A layer of grout may be placed in the mold and the wetted shredded rubber tire mixture is then placed in the mold on top of the grout layer and then dried into an environmentally sound insulating building block for green roof applications. A dry, environmentally sound, insulated building block for greening roofs includes an open matrix. In one embodiment, the environmentally sound insulating building block may further comprise an insulating foam disposed in the interior open matrix of the building block.

In one embodiment, the coated shredded rubber tire compound is poured into a mold to form the walls of the structure. In one embodiment, the coated shredded rubber tire compound is poured directly onto a scored concrete slab. In one embodiment, the coated shredded rubber tire mix is poured on top of a grout layer that has been placed on top of a scored concrete slab. The rod is inserted into the entire length of the mold so that the top can be laid over to compress the poured shredded rubber tire compound as it dries. The top may be plywood.

In one embodiment, a layer of coated shredded rubber tire compound is cast onto plywood to form a roof covering. A plurality of rods extend upwardly from the plywood layer to allow the top to be placed on top to compress the poured, coated shredded rubber tire compound as it dries.

Drawings

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

Fig. 1 depicts the construction of a typical IRMA.

Figure 2 illustrates an environmentally sound insulating building block for greening decking according to one embodiment of the invention.

Fig. 3A-3E depict various embodiments of environmentally-friendly, reliable insulated building blocks for greening roofing applications having environmentally-friendly, reliable insulated building blocks thereon for greening decking applications.

Figures 4A-4K depict steps for making an environmentally sound insulating building block for greenery paving applications according to one embodiment of the present invention.

Figures 5A-5H depict steps taken in constructing a structure that is entirely composed of an environmentally friendly insulating mixture of shredded rubber tire chips coated with silica fume, slag cement and cement, and mixed with water prior to casting the structure.

FIG. 6 depicts a roof system including environmentally responsible, reliable, insulated building blocks for green roof applications according to one embodiment of the present invention.

Figures 7A-7G depict steps for manufacturing environmentally responsible, reliable insulated building blocks for green roof applications according to one embodiment of the present invention.

Detailed Description

The present invention relates to environmentally friendly and reliable insulating building blocks for greening roofs and greening decking applications. An environmentally friendly and reliable insulating building block can provide high thermal insulation and strength. In addition, the green structure can be built in one monolithic casting.

In one embodiment of the present invention, an environmentally-friendly, reliable, insulated building block is provided for green roof applications. In this embodiment, an environmentally sound insulating building block is adhered to a waterproofing membrane adhered to the top layer of the insulation layer of a membrane roof system adhered to the roof base of a building.

An environmentally friendly, reliable, insulated building block for green roofing applications includes a coated shredded rubber chip having a top layer of dried grout, a block having four side surfaces that are substantially perpendicular to the side surfaces of the top and bottom surfaces, and a top surface including a layer of grout, wherein the environmentally friendly, reliable, insulated building block has a thickness defined by the distance between the top and bottom surfaces. Environmentally sound insulating building blocks, including coated shredded rubber compound and dried grout, are glued or otherwise adhered to the roof substrate of a building to provide an insulating layer for a membrane roof system. The waterproofing membrane is glued or otherwise adhered to the grout layer of the environmentally sound insulating building block. The environmentally friendly and reliable insulating building block of the present invention comprising a coated shredded rubber mixture and a dried grouted top layer is adhered to a waterproofing membrane. In one embodiment, the top of the environmentally sound insulated building block may be shaped in a manner that causes the liquid to flow in a desired direction, such as toward a drain.

In one embodiment, environmentally responsible, reliable insulating building blocks for green roof applications are positioned side-by-side with substantially similar environmentally responsible, reliable insulating building blocks and adhered to a roof substrate to provide an insulating layer for a membrane roof system. Gluing a waterproof membrane on top of an environmentally sound insulating building block for green roof applications, and then adhering the environmentally sound insulating building block for green roof applications to the waterproof membrane to form a green roof.

In one embodiment of the invention, an environmentally-friendly, reliable, insulated building block is provided for greenery surfacing applications. In this embodiment, environmentally safe insulated building blocks are adhered to a surface to provide a green decking to which growing media or tiles can be adhered. An environmentally friendly, reliable insulating building block for greening pavements includes a porous substrate through which water can flow freely.

An environmentally sound, insulated building block for green decking applications comprises a coated shredded rubber crumb dried into a block comprising a bottom surface, a top surface and four side surfaces substantially perpendicular to the bottom surface, the top surface comprising a permeable fire-resistant material, wherein the environmentally sound, insulated building block for decking applications has a thickness defined by the distance between the top and bottom surfaces. Environmentally sound insulating building blocks for decking applications comprising a coated shredded rubber compound and a permeable waterproofing material are glued or otherwise adhered to the base of a building roof to provide a porous decking to which growth media and/or tiles and tiles can be adhered.

In one embodiment, the permeable fire-blocking material comprises expanded slate.

In one embodiment, a plurality of environmentally sound insulating building blocks for roofing applications are adhered to a waterproofing membrane adhered to a top layer of an insulation layer of a roofing system adhered to a roof base of a building to provide a green roof. A second layer of environmentally responsible insulating building blocks having a top layer of permeable fire-blocking material is adhered to the top layer of the green roof to form a green decking. In one embodiment, the top of the environmentally sound insulating building block for green roof applications is tapered to create a "tilt to drain" roof system. The bottom surface of the environmentally responsible insulating building block for green paving is tapered to correspond to the tapering of the top of the environmentally responsible insulating building block for green roofing applications. The slope of the top and bottom of environmentally sound insulating building blocks for roofing and decking applications will direct the liquid to the roof drain. The permeability of environmentally sound insulating building blocks for green decking allows water to pass through and be directed to the roof drain.

In one embodiment, the shredded rubber tire pieces comprise shredded tires. In one embodiment, shredded rubber tire shreds are shredded to a size such that steel in the tire is removed, but nylon remains in the shredded rubber tire shreds. In one embodiment, the nominal size of the shredded rubber tire pieces is about 2 inches. In one embodiment, the shredded rubber tire pieces are greater than about 1/2 inches in size but less than about 2 inches in size. In one embodiment, the shredded rubber tire pieces are greater than about 1 inch but less than about 2 inches in size.

In one embodiment of the invention, the environmentally sound insulating building block has a thickness (measured from bottom surface to top surface) in the range of about 2 inches to about 20 inches, and a length and width (measured along side surfaces) of about 12 inches square. Other dimensions of environmentally sound insulating building blocks may be constructed in accordance with the principles of the present invention and these previous dimensions are listed as examples only and are not intended to limit the invention in any way.

In one embodiment, a green roof and green decking made from environmentally sound insulating building blocks conform to building codes designed to withstand severe weather conditions (e.g., high winds). For example, the 101.4.2 Florida Building Code (FBC) applies to "construction, installation, change, modification, repair, equipment, use and occupation, location, maintenance, removal and demolition of structures, both public and private, and sets forth the requirement that a building withstand the wind forces generated by the design wind speeds. In Broward County, Florida, the building must withstand 140mph, while in Miami-Dade County, Florida, the building must withstand 146 mph. Other standards also exist, such as ASCE (American society of civil Engineers) -7 and Florida regulations 553.844, in which the title "windstorm loss mitigation is specified; building construction standards for roof and opening protection requirements "; these criteria may also be applicable to replacement of roofs and decking.

In one embodiment, the coated shredded rubber tire compound is cast in a mold as a one-piece casting to form a wall structure. In one embodiment, the coated shredded rubber tire compound is poured directly onto a scored concrete slab. In one embodiment, the coated shredded rubber tire mix is poured on top of a grout layer that has been placed on top of the scored concrete panel. The rod is inserted into the entire length of the mold so that the top can be laid over to compress the cast coated shredded rubber tire compound as it dries. The top may be plywood.

In one embodiment, a layer of coated shredded rubber tire compound is cast onto plywood to form a roof covering. A plurality of rods extend upwardly from the plywood layer to allow the top to be placed on top to compress the cast coated shredded rubber tire compound as it dries.

Turning to the drawings, FIG. 1 depicts a typical IRMA 100. The sloped insulating roof layer 110 is adhered to the roof substrate 120. The waterproofing membrane 130 is adhered on top of the roof layer 110. An insulation layer 150 is placed on top of the drainage space 140. The drainage and ventilation layer 160 is formed on top of the insulation layer 150, and the insulation layer 150 may include a root barrier 165. The filter cloth 170 may be placed on the insulation layer 160. Gravel 180 and concrete tiles 190 may then be used to form the decking. The paving may also include a planting substrate 195.

FIG. 2 depicts an environmentally sound, insulated building block for greenery decking applications 200, comprising a bottom surface 201; a top surface 202 having a permeable layer of fire-blocking material 215; and four sidewalls 203. Shredded rubber tire shreds 205 have been coated with silica fume, slag cement and then mixed with water and dried to form an open matrix inside the environmentally sound insulating building block for greenery applications 200. In one embodiment, the permeable layer of fire-blocking material 215 comprises expanded slate that has been coated with silica fume, slag cement, and cement, then mixed with water, then placed in a mold, and then the wetted shredded rubber mixture is placed in the mold and dried to form an environmentally sound insulating building block for greenery paving applications 200.

Fig. 3A-3E depict various embodiments of environmentally-friendly, reliable insulated building blocks for greening roofing applications having environmentally-friendly, reliable insulated building blocks thereon for greening decking applications.

Fig. 3A depicts a side view of an environmentally responsible, thermally insulated building block for greenery roofing applications, overlaid with an environmentally responsible, thermally insulated building block for greenery decking applications. A plurality of environmentally sound insulating building blocks for green roof applications are adhered to the insulating layer 325 on top of the roof substrate 320 by the adhesive layer 312 to form a green roof 310. A waterproofing membrane 330 is adhered to the top of the green roof 310. A plurality of environmentally sound insulated building blocks for green decking applications, which have been covered with a permeable fire-blocking material 345 such as coated expanded slate, are placed on top of the grout layer 355 to adhere to the waterproof membrane 330 to form the green decking 350. The green decking 350 may include a growth substrate 380 and/or tiles 390. The green roof application 310 may include a growth medium 380 and/or tiles 390. The green paving 350 can include a planting substrate 395 and/or an artificial turf 397. The top surface of the green roof 310 may be sloped to drain water passing through the green decking 350 towards the drain 335.

FIG. 3B depicts a cross-sectional view of one embodiment of an environmentally sound insulating building block for greenery roofing applications overlaid with an environmentally sound insulating building block for greenery decking applications including turf. Environmentally-friendly, reliable, insulated building blocks for green roof applications are adhered to a waterproofing membrane 325 on top of a roof substrate 320 by a grout layer 312 to form a green roof 310. Waterproofing membrane 330 is adhered to the top of green roof 310. A plurality of environmentally sound insulated building blocks of coated shredded rubber tire chips for green paving applications are placed on top of the grout layer 355 to adhere to the waterproofing membrane 330 for use as green paving 350, which has been overlaid with a permeable fire-blocking material 345, such as coated expanded slate. The green decking 350 may include a growing medium 380 and/or tiles or bricks 390. The green roof 310 may also include a growth substrate 380 and/or tiles or bricks 390. The green decking may include artificial turf 397, which may be bonded to the top of the layer 345 of fire-resistant permeable material.

FIG. 3C depicts a cross-sectional view of one embodiment of an environmentally sound insulating building block for greenery roofing applications overlaid with an environmentally sound insulating building block for greenery decking applications including turf. Environmentally sound, reliable, insulated building blocks for green roof applications are adhered to the waterproof membrane layer 325 on top of the roof substrate 320 for use as a green roof 310. In this embodiment, the insulating panel 327 is adhered to the waterproof film 325 by use of an adhesive 328. A waterproofing membrane 330 is adhered to the top of the green roof 310. A plurality of environmentally sound insulated building blocks for green decking applications have been covered with a permeable fire-blocking material 345 (e.g., coated expanded slate) placed on top of the grout layer 355 to adhere to the waterproofing membrane 330 to form the green decking 350. The green decking 350 may include artificial turf 397 that may be bonded to the top of the layer 345 of fire-resistant permeable material.

Fig. 3D depicts a cross-sectional view of one embodiment of an environmentally responsible, insulated building block for greenery roofing applications overlaid with an environmentally responsible, insulated building block for greenery decking applications comprising paving or tile. Environmentally safe, reliable insulated building blocks for environmentally friendly roofs are adhered on top of a roof substrate 320 having a layer of grout 312 to form a green roof 310. Waterproofing membrane 330 is adhered to the top of green roof 310. A suitable reliable insulating building block of shredded rubber tires for the coating of the green decking which has been lined with a permeable fire-blocking material 345 (e.g. expanded slate) is placed on top of the grout layer 355 to adhere to the waterproofing membrane 330 to form the green decking 350. The green decking 350 may include tiles 390 bonded to the top of the layer 345 of fire-protecting permeable material with an adhesive 392.

Fig. 3E depicts a cross-sectional view of one embodiment of an environmentally responsible, insulated building block for greenery roofing applications overlaid with an environmentally responsible, insulated building block for greenery decking applications comprising paving or ceramic tiles. In this embodiment, environmentally sound insulating building blocks for green roof applications are adhered to insulating panels 327 and then adhered on top of roof substrate 320 using adhesive 328 to form green roof 310. The waterproofing membrane 330 is adhered to the top of the glass roof. A plurality of environmentally responsible, reliable, insulated building blocks of coated shredded rubber tire chips for green paving are placed on top of the grout layer 355, the top of the blocks having been laid with a permeable fire-blocking material 345, such as coated expanded slate. The waterproofing membrane 330 may be adhered to the waterproofing membrane 330 to form the greening decking 350. The green decking 350 may include paved tiles or bricks 390, the tiles or bricks 390 being bonded to the top of the layer 345 of fire-protecting permeable material by an adhesive 392.

Fig. 4A-4J depict steps for manufacturing environmentally-friendly, reliable insulated building blocks for green roof applications according to one embodiment of the present invention.

As shown in fig. 4A, a dry mixture is made from silica fume, slag cement and cement.

As shown in fig. 4B, shredded rubber tire pieces were added to the dry mixture and mixed until coated.

As shown in fig. 4C, water was added to the dry mixture of coated shredded rubber tire pieces until the dry mixture was completely wetted.

As shown in fig. 4D, the second dry mixture is made of silica fume, slag cement, and cement.

As shown in fig. 4E, a fire-blocking material such as expanded slate is added horizontally to the second dry mixture and mixed until coated.

As shown in fig. 4F, water is added to the dry mixture of coated fire-blocking material until the dry mixture is completely wetted.

As shown in fig. 4G, the molds are prepared and a layer of the wetted fire-blocking material mixture is added to the bottom of each mold.

As shown in fig. 4H, a wetted shredded rubber mixture is added to each mold on top of the wetted fireproofing mixture.

As shown in fig. 4I, each mold was fitted with a lid and placed in ambient air until dry.

The dry environmentally sound insulating building block is removed from the mold and is ready for use, as shown in fig. 4J.

Fig. 4K depicts an alternative mold form showing a sloped bottom such that the bottom surface of the environmentally responsible insulated building block when used in a green decking application corresponds to the tapered top of the environmentally responsible insulated building block when used in a green roofing application.

The order of mixing the ingredients can be varied by the operator as desired. For example, shredded rubber tire chips or waterproofing material (e.g., expanded slate) can be placed in a mixer and then a dry mixture of silica fume, slag cement, and cement added prior to mixing.

Fig. 5A-5H depict steps taken in building a structure made entirely of an environmentally friendly insulating mixture of shredded rubber tire chips coated with silica fume, slag cement and cement, mixed with water prior to integrally casting the structure.

Fig. 5A depicts a bag 505 filled with shredded rubber tire fragments 205 having a nominal size greater than about 1 inch but less than about 2 inches and a container 510 filled with a mixture of silica fume, slag cement and cement.

Fig. 5B shows that the bag 505 containing shredded rubber tire fragments 205 is added to a mixer 515 where they are mixed, and then the remaining dry ingredients (silica fume, slag cement and cement) are added and mixed to coat the shredded rubber tire fragments 205.

As shown in fig. 5C, water 520 is added to the coated shredded rubber tire pieces in a mixer 515 and mixed.

As shown in fig. 5D, wall molds 525 are constructed for the wall structure 527 on the foundation, and a grout layer 530 is placed on the foundation 535 at the bottom of each mold. A roof structure 529 is built on top of the wall mold 525. Metal rods are placed inside each mould and on the roof structure.

As shown in fig. 5E, the wet coated shredded rubber tire compound 540 is poured into a wall mold 525.

As shown in fig. 5F, the wet coated shredded rubber tire mixture 540 is poured on top of the roof structure 529.

As shown in fig. 5G, the plywood cover 545 is placed on top of the wetted coated shredded rubber tire mixture 540, which is poured on top of the roof structure 529, and the plywood cover 545 is attached to the metal rod 550, wherein the cover 545 is fastened when dry to compress the wetted coated shredded rubber tire mixture 540.

As shown in fig. 5H, once the wet coated shredded rubber tire mixture 540 is dried, the covering 545 and the mold 525 are removed and a structure made of an environmentally friendly insulating mixture having rubber tire chips coated with silica fume, slag cement, cement and water is formed.

Fig. 6 depicts one embodiment of a green roof application 600 that includes an environmentally sound insulating building block 610. The green roof application 600 includes a low-grade roof structure 620 comprising a metal or concrete decking 630 and a plurality of environmentally sound insulating building blocks 610.

An environmentally responsible insulated building block 610 is attached to a metal or concrete decking 630 using a high strength self setting grout 640, and a waterproofing membrane 650 is disposed over an adhesive or glue layer 625, the adhesive or glue layer 625 being disposed on the top surface 615 of the environmentally responsible insulated building block 610.

In one embodiment, waterproofing membrane 650 comprises any membrane known today or later developed for roofing or other construction purposes. The waterproof film 650 may vary according to the use and climate of the building.

Fig. 7A-7G depict steps for manufacturing an environmentally sound and reliable insulated building block according to one embodiment of the present invention.

As shown in fig. 7A, the dry mixture is made of silica fume, slag cement, and cement.

As shown in fig. 7B, shredded tire chips were added to the dry mixture and mixed until coated.

As shown in fig. 7C, water was added to the dry mixture until the dry mixture was completely wetted.

As shown in fig. 7D, molds are prepared and a layer of grout is added to the bottom of each mold.

As shown in fig. 7E, the wetted mixture is added to each mold until full.

As shown in fig. 7F, each mold was fitted with a lid and placed in ambient air until dry.

The dry environmentally sound insulating building block is removed from the mold and is ready for use, as shown in fig. 7G.

Examples of the invention

The following examples illustrate the manufacture and features of environmentally safe, reliable, insulated building blocks in more detail. These examples are merely illustrative, and are in no way limiting, or are intended to limit the scope of the invention.

Example 1.

The manufacture of environmentally friendly and reliable insulated building blocks for green paving applications.

About 1 gallon of silica fume (weighing 6.4 pounds), about 1 gallon of slag cement (weighing 9.2 pounds), about 1.5 gallons of portland cement (weighing 15.3 pounds) were mixed together for at least 2 minutes. The rubber tires were shredded to a size range of about 1/2 "to 2 inches, with the steel on the tires being removed, but the nylon on the tires remaining in the shredded rubber tire pieces. Seventy-five (75) pounds of shredded tire chips were added to the mixture, and the resulting mixture was then mixed for an additional five (5) minutes. Thereafter, 2 gallons of water was added to wet the dried shredded rubber tire mixture.

Separately, 3 gallons of expanded slate was mixed with 25.6 ounces of slag cement, 25.6 ounces of silica fume, and 38.4 ounces of portland cement for at least five (5) minutes. Thereafter 51.2 oz of water was added to wet the dried expanded slate mixture.

A layer of wet shredded rubber tire mix was poured into a mold of 12 inches by 4 inches deep to which about 1 inch of wet expanded slate mix had previously been added. The mold was filled and covered with a lid and allowed to dry at room temperature in the environment for 5 days. Once the mixture dries in each mold, the resulting environmentally responsible insulating building block is removed and ready for use in greendecking applications.

Example 2

An environmentally sound insulating building block for green-paving applications was prepared as described in example 1, except that the bottom of the mold was inclined. A dry environmentally sound insulating building block has an inclined top surface comprising expanded slate.

Example 3

[ manufacture of environmentally friendly and reliable insulating building blocks for greening roof applications.

1 gallon of silica fume (weighing 6.4 pounds), about 1 gallon of slag cement (weighing 9.2 pounds), and about 1.5 gallons of portland cement (weighing 15.3 pounds) were mixed together for at least 2 minutes. The rubber tires were shredded to a size range of about 1/2 "to 2 inches, with the steel on the tires being removed, but the nylon on the tires remaining in the shredded rubber tire pieces. Seventy-five (75) pounds of shredded tire chips were added to the mixture, and the resulting mixture was then mixed for an additional five (5) minutes. Thereafter, 2 gallons of water was added to wet the dried shredded rubber tire mixture. When the mixture was fully wetted, the mixture was poured into a mold having dimensions of 12 inches by 12 inches and a thickness of about 4 inches, which had been previously added with 1/2 inches of grout. The mold was filled and covered with a lid and allowed to dry at room temperature in the environment for 5 days. Once the mixture is dried in each mold, the resulting environmentally responsible insulating building block is removed and then attached to the metal or concrete decking on top of the building using a high strength self-setting grout. The waterproofing membrane is placed on an adhesive or glue layer that is disposed on the top surface of the environmentally sound insulating building block. Thereafter, in green roof applications, a plurality of environmentally sound insulating building blocks prepared according to example 2 were adhered to a waterproofing membrane.

Example 4

Environmentally-friendly, reliable insulating building blocks for green-decking applications were tested individually and attached to various roof systems, and the following tests were also conducted for the environmentally-friendly, reliable insulating building blocks for green-roofing applications described in example 3: testing wind uncovering resistance; a class a fire rating; testing the resistance to plucking in the field; testing the metal edge adhesion; sound transmission loss; performing compression test; steady state heat transfer performance; a flow of water; aging test; and recyclable components, and physical property testing. The results are as follows.

TAS 114-95 wind uncovering resistance test

Environmentally friendly, reliable insulation building blocks for green roofing applications with foam adhesive attached to 2 "extruded polystyrene insulation layer-502.5 PSF with no failure record

An eco-friendly reliable insulating building block for greenery decking applications on an eco-friendly reliable insulating building block for greenery roofing applications foam adhered to a 2 "polystyrene insulation layer-at 387.5PSF failure

A tile laid on an environmentally responsible, reliable, insulated building block for greenery decking applications above an environmentally responsible, insulated, reliable, insulated building block for greenery roofing applications attached to a concrete slab with grout-at 400PSF failure

Artificial turf on environmentally sound insulating building blocks for greenery surfacing applications on top of environmentally sound insulating building blocks for greenery roofing applications attached to a concrete slab with grout-failure at 330PSF

Environmentally-friendly, reliable, insulated building blocks for green roof applications attached to concrete slabs by grouting-failure at 222.5PSF

Tiling on eco-friendly reliable insulating building blocks for green decking applications on eco-friendly reliable insulating building blocks for green roofing applications attached to 2 "polystyrene insulation-at 300PSF failure

UL 790A fire rating

4 "environmentally sound insulating building blocks for green roof applications, capable of no-fire testing-passing at 11/2 feet of infinite slope

A 4 "thick environmentally sound insulated building block with artificial turf slope 1/4" for greenery paving applications. 30 inch no ignition test-pass for melt on test sample

A 4 "thick environmentally sound insulated building block with artificial turf slope 1/4" for greenery paving applications. Melt on test sample 27 inches no ignition test-pass

4 "thick environmentally-friendly, reliable insulating building blocks for 3" slope green roof applications. 2 feet surface charcoal no ignition test-pass

TAS-105 field plucking resistance test

Ten environmentally sound insulated building blocks for green decking applications were tested for resistance to plucking. The Fasteners used were Olympic Fasteners, inc. 3-1/2 "spade pillow Fasteners. The estimated value "t" was chosen based on the statistical 95% probability Tvp of 2.262. The calculated average FM ═ a/n (sum fi) ═ 364.0. The calculated standard deviation (SF) ═ Sqrt [ ((1/N-1) (Sum (Fi-FM) ^2)) ] ═ 110.294. % deviation (PD) 30.30%. According to TAS 105-11(FBC2114& FM 1-52), F2014 ═ FM- (Tvp) (SF/Sqrt N), where F2014 ═ 285.11. MCRF14 (minimum characteristic resistance) F2014 285.11.

TAS-111(B) -95 Metal edge adhesion test

PRI Construction Materials Technologies, Inc. Water drip edge pull value tests were performed on environmentally sound insulating building blocks for green roof applications. Starting with a 300lbf load, horizontal loads were applied in 50lbf increments for 60 seconds. After each loading interval, the load was reduced to zero and held for 120 seconds before increasing the load in 50lbf load increments. The mean failure load was 350lbf and the maximum pressure was 1050 psf.

ASTM E90-09 sound transmission loss

An environmentally-friendly and reliable heat-insulating building block STC 39OITC 36 for greening roof applications

ASTM C39 compression test

Environmentally friendly, reliable, insulated building blocks for roofing applications

80PSI 7 days

89PSI 28 days

28 days 96PSI

94PSI 56 days

Environment-friendly and reliable heat insulation building block suitable for greening pavement application

7 days 96PSI

89PSI 28 days

83PSI 28 days

87PSI over 56 days

ASTM for steady state heat transfer characteristics by means of thermal flow meter devices C-518 standard test method

An environmentally friendly and reliable insulating building block R-1.3127 per inch suitable for greening paving applications

UL flow rate of water through environmentally-friendly and reliable insulated building blocks for green paving applications

4' thick environmentally friendly reliable insulated building blocks for green paving applications

After 20 seconds of prewetting time, 8 lbs of water were poured, 7.4 lbs of water were collected, and 0.6 lbs of water was retained

After 35 seconds of testing time, 40 pounds of water were poured, 38.7 pounds of water were collected, and 1.3 pounds of water were retained

12 "thick samples

After 55 seconds of prewetting time, 8 pounds of water were poured, 6.6 pounds were collected, and 1.4 pounds of water were retained

After 65 seconds of testing time, 40 pounds of water were poured, 38.4 pounds of water were collected, and 1.6 pounds of water were absorbed.

Aging test

PRI Construction Materials Technologies, Inc. an environmental-friendly, reliable, insulated building block for green roof applications was subjected to an aging test by exposure to ultraviolet light at a constant temperature for 5000 hours under an AC 48UV lamp.

Physical Property testing

PRI Construction Materials Technologies, Inc. environmental and reliable insulated building blocks for green roofing applications were tested for physical properties, particularly flexural strength of concrete using ASTM C293-16, and impact resistance of UL 2218.

ASTM C293-Pre-Weathering: 367 pounds; after weathering: 415 pounds. (5000 hours AC 48 ultraviolet weathering)

UL 22184 class impact hail test (Steel ball) -pass

Recovery amount

Environmentally-friendly, reliable, insulated building blocks for green roofing applications and environmentally-friendly, reliable, insulated building blocks for green paving applications have both been certified by the recycling composition of SCS Global Services.

An environmentally friendly and reliable insulating building block-4' thick-recovery 87.53% by volume for greening roofs

An environment-friendly and reliable heat-insulating building block-8' thick for greening roofs with a recovery amount of 90.57% by volume

An environmentally friendly, reliable, thermally insulating building block for greening roofs-4' thick-80.59% recovery by volume

Environmentally friendly reliable insulating building blocks for green paving applications-8' thick-86.18% recovery by volume

Maximum design pressure (Steel paving)

A plurality of environmentally sound insulating building blocks for green roofing applications having 1/4 "slopes were adhered to a min.22ga 1.5" type B galvanized steel decking using AH-160propack adhesive continuous 1-1/2 inch beads spaced 6 "o.c. apart. A 8000psi structural concrete surface was adhered to the top surface of a plurality of environmentally sound insulating building blocks for green roofing applications and a NOA approved fully adhered roofing system was applied thereto. The maximum design pressure measured was-292.5 psf.

Example 5

The coated shredded rubber tire mixture of example 3 was used to build a structure with four walls and a roof. A scored concrete slab is used as the foundation for the structure. A wall mold approximately twelve (12) inches thick is constructed and a layer of grout is laid over the scored concrete slab at the bottom of the mold. The metal rod is inserted from the bottom so that it extends beyond the top of the mold. Plywood was placed on top of the cast coated shredded rubber tire mix to compress the mix as it dried. A roof structure is built on top of the walls using plywood. A layer of twelve (12) inch thick coated shredded rubber tire compound was cast onto plywood to form a roof. Thereafter, the roof is coated with stucco and a roof coating. A plurality of rods extend upwardly from the plywood layer to allow the top to be placed over the poured, coated shredded rubber tire compound to compress it when dry.

The included structures were tested and found to have a load carrying capacity of 20,106 pounds. During the test, the structure sagged 1/4 inches due to the weight load, but when the weight was removed, the sag decreased to 1/8 inches. The structure was measured to have an R value of 15.72 and a recovery of about 93.83%.

In the foregoing specification, the invention has been described with reference to specific exemplary embodiments thereof. It will be evident to those skilled in the art that changes and other embodiments or modifications may be made which utilize the principles of the present invention without departing from the broader spirit and scope of the invention. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.