Modular Assembly System with Multiple Global Applications

Mr. Peter Roberts

Use of fossil fuels is warming earth's climate and is producing adverse effects for life on earth. The system described reduces emissions, creates more efficient combustion, and provides methods for reducing effects created by global warming. These effects include rising sea level, increased storm activity, impacts on coastal areas, loss of freshwater, loss of trees, and the increased need for food and potable water. The approach to solving these problems utilizes existing infrastructure:
including manufacturing facilities, distribution networks, construction teams, architectural codes, and design organizations. This methodology recognizes the large positive effect to be realized by thoughtful implementation of an idea within an existing framework. The technological applications that can be implemented from this approach have multiple bearings on the problem described above. The strategy implements a novel modular system for assembly, which creates highly efficient furnaces, ovens and kilns. This modular system is used to create high strength structures appropriate for hurricanes, tornadoes and violent weather. This system is used to build underwater structures, including levees and breakwaters. This system can be used to create freshwater from saltwater by utilizing water pressure at depth to force saline solution through a salt-filtering membrane. Finally this approach is suitable for construction of extraterrestrial structures, including lunar and Martian bases using material found on-site. This strategy relies on a modular system comprised of interlocking triangular blocks, which assemble into a sphere, dome, arch, cylinder, straight wall, or any combination of these elements. This technology is unique because it allows for an interlocking feature to be produced on a simple two-piece mold such that the resulting modular shape creates no undercut, or draft, as it is released from the mold. This is accomplished by an articulated block design that employs a high level of symmetry, and creates an interlocking feature while allowing a tensile member to be woven into the structure between abutting block faces. This modular design is appropriate for mass production using currently available methods, equipment and materials that are utilized globally.

Describe the critical need your solution addresses.

Patents have been issued for this technology, including US patents 5296180, 5298205, 5329707, 5458837, 5560151, 5732518, 5873206 and 6076318, among others.

Advanced prototypes using this technology have been built. These prototypes were made using existing concrete block machines and state-of-the-art refractory brick production methods.

This technology has been featured in publications, including Popular Science, Concrete International, Journal of Light Construction and Aberdeen’s Journal of Masonry Construction.

Papers on this technology have been presented to the American Ceramic Society at their annual conference. http://f1.grp.yahoofs.com/v1/kH8QSc2I_QWGnw6aCtaTqrfWcm7W2nWfJS-ntiuEd1u... (see part2 also)

The New York State Energy Research & Development Authority has awarded two grants for the development of this technology, for over $420,000. This work showed an increase in efficiency of 37% over the current state-of-the-art.

Currently this technology is being utilized at a glass blowing studio in Park City, Utah (“The Glory Hole, Inc.”). This facility is producing these modular units as glass block, used together with manufactured concrete block. High-end market entry.

Besser Company, the world’s largest manufacturer of concrete block machines, is working with me to create (free) high-carbon steel molds for their equipment in Alpena, MI. Teaming with this global company allows for global marketing and implementation of this technology.

Organized labor is working with me on developing methods of construction using this system. This includes the Bricklayers and Allied Craftworkers Union.

Use of any BFI funds will assist in the construction and deployment of this system globally, creating a multiplier effect.

Explain your initiative in more depth and its stage of development.

This strategy uses technology to increase efficiency where industrial manufacturing requires combustion, thus reducing greenhouse gases. This same system is applicable toward inexpensive, high performance, environmentally responsible housing. The technology is also suitable for high strength underwater structures. This application can also implement a patented method for producing micro-porosity within the blocks (using vital wheat gluten) to create a filter system as a large ceramic sphere, to create fresh water from salt water. This porous ceramic system is also patented for hydroponic growth media, and is readily deployed in highly efficient farming.

Development of this system holds multiple applications with profound effects for addressing current problems of humanity.

This system is ecologically responsible. It reduces greenhouse gases, does not require wood (cutting trees), has a very long life cycle, creates freshwater, and can be used for efficient hydroponic farming.

How does your strategy and approach respond creatively and comprehensively to key issues?

Peter Roberts received his degree in Masonry Science from the New York State College of Ceramics at Alfred University. His expertise is in kiln, furnace, oven and architectural masonry systems. His work has been patented, developed, and employed in numerous relevant applications.

Mr. Roberts’ work was recognized in the “Identification of Cutting Edge Technologies” initiative of the American Concrete Institute, the leading global organization for developing codes and practices within the concrete industry.

Besser Company is the world’s leading producer and service agent for the concrete block industry. This company provides the means to implement this technology globally, creating a significant multiplier (trimtab) effect.

Mr. Roberts’ experience and practice of working with various ceramic materials provides the know-how to implement this technology in various embodiments.

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