CONCRETE MIX AND PRODUCTS INCLUDING RECYCLED PORCELAIN

Abstract

A concrete mix for use in forming molded concrete end products is disclosed. The concrete mix includes treated porcelain kernels, cement and sand. The treated porcelain kernels are formed from recycled and currently unusable porcelain products. The porcelain products are crushed and processed to create porcelain kernels having a desired size. The porcelain kernels having the desired size are mixed with cement and sand and the concrete mix is packaged for subsequent use. The concrete mix including the porcelain kernels formed from recycled porcelain products allows the porcelain end products to be recycled while providing concrete products that have lighter weight and greater flame resistance.

Claims

1-7. (canceled)

8. A method of forming a concrete mix, comprising the steps of: receiving a supply of recycled porcelain, wherein the recycled porcelain is obtained from recycled porcelain consumer products; processing the recycled porcelain to create finished porcelain kernels; mixing the finished porcelain kernels with at least cement and sand to create the concrete mix; and packaging the concrete mix for use in forming an end product.

9. The method of claim 8 wherein the porcelain kernels have a size in the range between 0.0117 to 0.750.

10. The method of claim 9 wherein the treated porcelain kernels have a most preferred sizing between 0.265 and 0.375.

11. The method of claim 8 wherein the treated porcelain kernels constitute at least 35% of the concrete mix by weight.

12. The method of claim 8 wherein the cement includes fly ash and at least 30% of the packaged concrete mix by weight is formed from recycled porcelain and fly ash.

13-18. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The drawings illustrate the best mode presently contemplated of carrying out the disclosure. In the drawings:

[0018] FIG. 1 is a schematic view of a countertop created in accordance with the present disclosure;

[0019] FIG. 2 is a magnified, section view of the concrete formed utilizing the concrete mix of the present disclosure:

[0020] FIG. 3 is a section view illustrating a sample mold used to form a concrete countertop utilizing the concrete mix of the present disclosure;

[0021] FIG. 4 is a section view similar to FIG. 3 showing the disbursement of the porcelain kernels within the molded countertop; and

[0022] FIG. 5 is a flowchart illustrating the steps utilizing the method of the present disclosure.

DETAILED DESCRIPTION

[0023] FIG. 1 illustrates one potential use for a concrete end product utilizing the concrete mix of the present disclosure. Although one type of concrete end product (countertops) is illustrated in FIG. 1, it should be understood that various different types of end products could be formed utilizing the concrete mix of the present disclosure. Theses concrete products can include both decorative and structural products that are typically formed from concrete.

[0024] In the embodiment shown in FIG. 1, the concrete mix is used to form a countertop 10 that can be installed in a kitchen 12. The countertop 10 includes a cutout that can receive a sink 14. The countertop 10 includes an edge surface 16 that is formed to provide a decorative and pleasing appearance.

[0025] Presently, it is known to form countertops 10 such as shown in FIG. 1 from various compositions of material that form concrete. Typically, concrete includes a mixture of sand, cement, water and an aggregate material, such as stone or pea gravel. In accordance with the present disclosure, the concrete mix used to form the countertop 10 includes a mixture of cement, sand, water and porcelain kernels formed from recycled porcelain end products.

[0026] Referring now to FIG. 2, a section view of the concrete formed in accordance with the present disclosure includes the series of porcelain kernels 18 bound together by the mixture of cement, water and sand which forms the binding material 20 between the separate porcelain kernels 18. The porcelain kernels 18 are illustrated having irregular outer surfaces that are created during the crushing of porcelain end products that are being recycled to provide the source of porcelain for the concrete mix. The specific shape of the individual porcelain kernels 18 varies depending upon the processing techniques utilized and the source of recycled porcelain.

[0027] In accordance with the present disclosure, the porcelain kernels 18 are formed from porcelain products that are being recycled to create the concrete mix. Throughout the present disclosure, the term recycled porcelain will be used to refer to porcelain obtained from both post-consumer porcelain products as well as pre-consumer porcelain product or waste. As an example, a post-consumer porcelain product, such as a sink, vanity top, toilet or other similar type of porcelain product can be used to form the porcelain kernels 18. In addition to post-consumer porcelain products, the porcelain kernels 18 could also be generated from post-manufacturing, pre-consumer porcelain products that cannot be used in the manner which was intended. As an example, a porcelain sink that was damaged in transit or at the manufacturing facility and cannot be used as a sink could be utilized as a recycled supply to create the porcelain kernels 18. The porcelain used to create the porcelain kernels may be pre-consumer or post-consumer products of any size, color, shape or age.

[0028] In the embodiment shown in FIG. 2, the porcelain kernels are formed from recycled pre- or post-consumer products. It is desired that the porcelain kernels 18 have a size A shown in FIG. 1 in the range of 0.0117 to 0.750. In the most preferred embodiment, each of the kernels will be in the range of 0.265 to 0.375. The size of the porcelain kernels will affect the strength and durability of the concrete formed from the porcelain kernels 18 created from the recycled porcelain material. In the embodiment shown in FIG. 2, the countertop, or other molded product, formed from the concrete mixture that includes the porcelain kernels will have a weight savings of approximately 30% compared to similar commercial offerings for countertops, such as those formed from granite, marble, concrete, limestone, quartz or soap stone. In addition to the weight savings, an end product that is formed from the concrete mix including the porcelain kernels will increase the fire rating of the product by as much as 50% as compared to concrete formed with stone or pea gravel. The use of the porcelain kernels in the concrete shown in FIG. 2 creates a thermal break in the concrete unit's substrate, which leads to the increase in the fire rating.

[0029] In addition to being used as the source of aggregate in the concrete mix, it is contemplated that the recycled porcelain could be ground into very small pieces or particles such that the recycled porcelain would have the general consistency and texture of sand. In such an embodiment, the fine particle recycled porcelain could be used in the place of sand when forming concrete. Such an embodiment would increase the amount of recycled components in the concrete mix.

[0030] When a concrete product, such as a countertop, is formed from the concrete mix shown in FIG. 2, the countertop will qualify for the LEADS Program (Leadership In Energy And Environmental Design) through the U.S. Green Building Institute. The current qualification requires that the products must include a minimum of 20% post-consumer products or 50% post-industrial. The concrete mix in accordance with the present disclosure includes a minimum of 35% post-consumer products. The 35% post-consumer products include both recycled porcelain and cement that may or may not include recycled fly ash. Additional LEAD points will be given when the credit level requirements for the recycled content are exceeded, such as if the recycled porcelain and cement exceeds the 35% threshold.

[0031] In accordance with one embodiment of the present disclosure, the concrete mix includes porcelain kernels that constitute at least 35% of the mixture by weight. The concrete mix will include a mixture of the porcelain kernels, cement and sand. The porcelain kernels will form at least 35% of the mixture by weight.

[0032] In yet another embodiment that maximizes the amount of recycled components used in the concrete mix, a portion of the cement could be replaced with fly ash and the sand could be replaced with recycled porcelain ground into fine particles. Such an embodiment would increase the number of LEAD points.

[0033] When the concrete mix is used to form countertops, such as shown in FIG. 1, the countertop can be polished to expose the pores formed in the recycled porcelain kernels. The pores thus provide a visually pleasing appearance to the top surface of the countertop.

[0034] In addition to utilizing the concrete mix for countertops, such as shown in FIG. 1, it is contemplated that the concrete mix including the recycled porcelain could be utilized to form other end products, such as roofing tiles, vertical concrete columns or pillars, plaster mix, redi-mix, stucco, floor tiles and any other type of end product that is currently being formed from concrete that includes stone aggregate and/or sand. As described above, the concrete mix including the porcelain kernels will have approximately 35% less weight and thus can be utilized in applications in which the weight of a concrete product previously prohibited the use of concrete.

[0035] FIG. 3 illustrates a cross-section view of a countertop mold that will utilize the concrete mix of the present disclosure. In the embodiment shown in FIG. 3, an expanded metal/diamond mesh 22 is utilized within the concrete mold. In addition to the mesh 22, the mold can also include concrete wire 24 and rebar 26 to provide further structural integrity for the product formed from the concrete mix. In the embodiment shown in FIG. 3, the concrete wire has 66 openings or smaller and the wire has a diameter of between and 3/16. In the embodiment illustrated, rebar 26 is included for structural purposes. However, it is contemplated that the rebar 26 could be eliminated while operating within the scope of the present disclosure.

[0036] In the embodiment shown in FIG. 3, the product 28 has an overall thickness B of approximately 1.75 at a minimum. The product 28 has a first layer 30 between the top surface 32 and the mesh 22. In the embodiment shown, the top layer 30 has a thickness of approximately 0.50. An intermediate layer 34 formed between the mesh 22 and the rebar 26 has a thickness of approximately 0.75 while a third layer 36 between the rebar 26 and the bottom surface 38 has a thickness of approximately 0.50. Although exemplary dimensions are shown in the embodiment of FIG. 3, it should be understood that the thickness of the product 28 could be varied depending upon user requirements.

[0037] FIG. 4 illustrates the product 28 as including the porcelain kernels 18 distributed throughout the thickness of the product. The porcelain kernels 18 are balanced and equally distributed throughout the thickness B of the end product 28. Each of the porcelain kernels 18, as previously discussed, is a fractured component and is not of a smooth, defined surface. The fractured outer surface of the porcelain kernels 18 enhances the adhesion of the cement within the concrete mix.

[0038] FIG. 5 illustrates one method of creating the concrete mix in accordance with the present disclosure. As illustrated in FIG. 5, the method first includes the step of receiving recycled post-consumer and/or pre-consumer porcelain products, illustrated by reference numeral 40. The post-consumer products can include various different types of finished materials formed from porcelain, such as sinks, vanity tops, toilets or any other type of product that is formed from porcelain. Although step 40 shows the use of post-consumer and pre-consumer products, it should be understood that any other porcelain product that is currently undesirable and is being discarded could be utilized. As an example, pre-consumer products, such as a sink that is damaged in transit or during the manufacturing process and can no longer be used for its intended purpose, could be part of the porcelain products received in step 40.

[0039] Once the porcelain products being recycled and received in step 40, the porcelain products are processed to create porcelain kernels. Typically, this processing will include crushing and breaking of the consumer product that is formed from porcelain. During this processing step 42, the porcelain products are crushed until the kernels reach a desired kernel size. In step 42, the method sorts the kernels such that kernels smaller than a desired size and those larger than a desired size are discarded. Kernels that have a size too large are returned for further processing while kernels of a size less than a minimum are discarded for other use. As discussed previously, the desired size for the porcelain kernels is in the range of 0.0117 to 0.750. The most preferred size range for the porcelain kernels is in the range of 0.265 to 0.375.

[0040] Once the desired porcelain kernel sizes have been separated, the porcelain kernels are combined with cement and sand to form the concrete mix, as shown in step 46. Although a concrete mix is described as including sand, the mix could be formed without sand and could incorporate very fine particles of recycled porcelain. As indicated above, it is desired that the porcelain kernels form at least 35% of the concrete mixture. Further, the concrete mix can also include a cement/fly ash mixture that further increases the recycled components of the concrete mix. In an embodiment in which both the porcelain kernels and cement/fly ash are drawn from recycled products, it is desirable that the combination of the porcelain and the recycled cement/fly ash constitute at least 65% of the mix by weight.

[0041] Once the concrete mix is formed in step 46, the concrete mix is packaged in step 48 for use in forming concrete products. The packaging step 48 can place the concrete mix into 50 lb. bags, or any other size as desired. Alternatively, the packaging step can be eliminated and the concrete mix used immediately to form concrete products, such as countertops.

[0042] Once the concrete mix has been packaged, the concrete mix can be shipped or sold to concrete countertop manufacturers and installers for the creation of concrete countertops having a desired shape and size. The concrete mix can be dyed or colored to meet any decorative look for a home or business owner.

[0043] In addition to utilizing the concrete mix for forming countertops, it is understood that the concrete mix could be utilized to form many other different types of decorative and structural concrete products while operating within the scope of the present disclosure.

[0044] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.