초록 ▼

A culm block and a method of manufacture are disclosed. The culm block comprises a plurality of straw stalks forming a first rigid wall and a second rigid wall as a result of an application of heat and pressure to the same and the inherent bonding agent found in the straw stalks. Preferably, the cul

A culm block and a method of manufacture are disclosed. The culm block comprises a plurality of straw stalks forming a first rigid wall and a second rigid wall as a result of an application of heat and pressure to the same and the inherent bonding agent found in the straw stalks. Preferably, the culm block further comprises a plurality of through-holes for receiving structural reinforcements or otherwise and a restraining device wrapped about the block for added structural support.

대표청구항 ▼

What is claimed is: 1. A method of forming a building block structure comprising the steps of: a) providing a mass of randomly oriented straw stalks that includes rice straw stalks; b) shaping the mass of straw stalks into a block that includes a first wall and a second wall and sidewalls orthogona

What is claimed is: 1. A method of forming a building block structure comprising the steps of: a) providing a mass of randomly oriented straw stalks that includes rice straw stalks; b) shaping the mass of straw stalks into a block that includes a first wall and a second wall and sidewalls orthogonally connected to the first wall and the second wall, and defining a width that includes the first wall, the second wall and an intermediate block portion connecting the first wall and the second wall; c) forming at least one through hole in the intermediate block portion that extends between opposing connecting sidewalls; d) applying an added binding agent to the block or independently to the straw stalks to bond the straw stalks together; and e) applying pressure in the range of 1250 to 2000 psi to the mass of straw stalks at a temperature of about 250 to 350° F. for a period of approximately 20 to 30 minutes so that at least the first wall and the second wall locally densify to form a rigid skin portion that has a density greater than the intermediate block portion, the rigid skin portion being generally smooth, and of sufficient density that it receives and supports fasteners. 2. The method of claim 1, wherein the rigid skin is generally planar. 3. The method of claim 1, wherein the added binding agent is non-toxic. 4. The method of claim 1, further comprising a step of forming indentations, projections, grooves in one or more of the walls. 5. The method of claim 1, further comprising a step of forming the at least one through hole using a cutting device. 6. The method of claim 1, wherein the applying pressure step is performed so that the rigid skin portion has a thickness of about 3.125% to about 6.25% of the width of the block. 7. The method of claim 1, wherein the applying pressure step is performed so that the rigid skin portion has a thickness of about ½ to ¾ inch. 8. The method of claim 1, further comprising a step of preventing moisture from entering and remaining within the block. 9. The method of claim 1, further comprising a step of forming a wall by matingly-engaging the block with another block. 10. The method of claim 6, further comprising a step of fastening an additional layer directly to the block. 11. The method of claim 7, further comprising a step of fastening an additional layer directly to the block. 12. The method of claim 1, wherein the step of heating includes heating through any through hole. 13. A method of forming a building block structure comprising the steps of: a) providing a mass of randomly oriented straw stalks that includes rice straw stalks; b) shaping the mass of straw stalks into a block that includes a first wall and a second wall and sidewalls orthogonally connected to the first wall and the second wall, and defining a width that includes the first wall, the second wall and an intermediate block portion connecting the first wall and the second wall; c) forming at least one through hole in the intermediate block portion that extends between opposing connecting sidewalls; d) applying an added binding agent to the block or independently to the straw stalks to bond the straw stalks together; and e) applying pressure in the range of 1250 to 2000 psi to the mass of straw stalks at a temperature of about 250 to 350° F. for a period of approximately 20 to 30 minutes so that at least the first wall and the second wall locally densify to form a rigid skin portion that has a thickness of about 3.125% to about 6.25% of the width of the block and a density greater than the intermediate block portion, the rigid skin portion being generally smooth, and of sufficient density that it receives and supports fasteners. 14. The method of claim 1, further comprising a step of forming a wall by matingly-engaging the block with another block. 15. The method of claim 13, further comprising a step of heating through the at least one through hole. 16. The method of claim 14, further comprising a step of heating through the at least one through hole, and attaching a restraining device to the block.