Rebecca Lane Stephens

US Patent:

20110227260, Sep 22, 2011

Filed:

Mar 16, 2011

Appl. No.:

13/048962

Inventors:

John W. North - Tucker GA, US
Maurice W. Lashley - Lawrenceville GA, US
Larry D. Sheppard - Lawrenceville GA, US
Rebecca A. Stephens - Tucker GA, US

Assignee:

JWN, INC. - Atlanta GA

International Classification:

C04B 33/32

US Classification:

264610

Abstract:

Cellular ceramic materials, for example closed cell glass ceramic materials, for use in construction of buildings comprising a clay material, carbon, and water used to form the cellular ceramic blocks, slabs and beams by expansion of the particles inside the ware. The cellular ceramic materials are produced by first mixing the clay, carbon and about 40% to about 70% water by weight of the clay in the mixture, allowing the mixture to cure, drying the cured mixture, then firing the dried mixture at a temperature and for a period of time sufficient to melt the surface of the mixture. The clay material can be, for example, surface clays, ball clays, kaolin, shale, fly ash and/or bentonite. In another embodiment a mixture of volcanic ash, carbon and water can be formed and layered with the mixture of clay, carbon and water. The cellular ceramic materials are, in most cases, impervious to liquid, are capable of supporting substantial loads in tension and compression without reinforcement, and require no additional insulating material. Such cellular ceramic material may also be used in the construction of buildings with a metal skeleton comprising metal bars forming a structure for supporting the cellular ceramic building material.