Intellectual Property Office

Non-Confidential Disclosures

"Low Temperature Process to Create Bricks"

PSU Invention Disclosure No. 2006-3160

Field of the Invention/Key Words:

Construction, Residential, Industrial and Other; Carbon Emissions Reduction

Inventors:

M. Diop, et al.

Background:

The manufacturing of bricks is an energy-intensive industry that contributes significantly to carbon dioxide emissions (http:www.epa.gov/ttn/chief/ap42/ch11/final/c11sO3.pdf) (see attachment). Emissions from brick manufacturing facilities include particulate matter (PM): PM less than or equal to 10 μm in aerodynamic diameter (PM-10) and PM less than or equal to 2.5 μm in aerodynamic diameter (PM-2.5), sulfur dioxide (SO2), sulfur trioxide (SO3), nitrogen oxide (NOx) carbon monoxide (CO), carbon dioxide (CO2), metals, total organic compounds (TOC), including methane, ethane, volatile organic compounds (VOC), and some hazardous air pollutants (HAC), hydrochloric acid HCl and fluoride compounds. More than 50 chemical pollutants are generated by the process. In 2002, over eight billion bricks were sold in the United States. Typically, bricks are made by firing clay to approximately 2,000 °F. Considering the fact that the manufacturing of one brick consumes around 2 Mega Joules/kg brick, the total energy used in the U.S. can be estimated at sixteen billion Mega Joules/kg brick. The heating process changes the molecular structure of the clay, such that it is vitrified. Variations in a brick’s color, texture and performance characteristic may be made by changes in the mixture of clay, shale, water, air as well as any other special additives or coatings. Brick is the leading wall cladding material for the commercial market, while retaining a strong presence in the residential market, which consumes over eighty percent of all bricks made.

Invention description:

The subject invention is a low temperature emission process to make bricks. The process occurs at near ambient temperatures and does not generate any pollutants (gases or particles). The process time lasts for several hours. The starting materials can consist of natural materials as well as by product materials. As such, the inventors believe that the process is more cost efficient than standard practices used in the industry. The characteristics of the brick covered by this invention include a controllable range of colors from red to brown. Research results have shown that the ultimate compressive resistance of the invention’s bricks range from 10 – 20 mPa, depending on processing conditions. This strength can be closely controlled by the process conditions (concentration, fineness, time of curing, etc.). These results suggest a marked improvement over bricks currently on the marketplace. Other characteristics, including water resistance, are comparable to existing bricks. Leaching tests show that structure of the mineral that forms during the process remain stable. Bricks generally have low solubility and projected durability. More testing is needed to verify these characteristics.

Contact:

Matthew D. Smith
Sr. Licensing Officer
Intellectual Property Office
The Pennsylvania State University
113 Technology Center
University Park, PA 16802-7000
Phone: (814) 863-1122
Fax: (814) 865-3591
E-mail: mds126@ psu.edu