Apparatus and methods of forming and manufacturing cob products, cob products, and structures comprising the same

Abstract

Apparatus 50 for forming cob product 30, comprising volume 56 with first and second openings 58, 60, a press 51 and a cover 64, the press 51 closes the first opening 58 and the cover 64 closes the sec

Claims

1. Apparatus for manufacturing cob products, the apparatus comprising: an enclosed chamber defining an interior volume and having a first opening and a second opening;a press configured to apply a compressive force to the interior volume of the chamber; anda cover;wherein the press is operable to close the first opening of the chamber;wherein the cover is operable to close the second opening of the chamber;andwherein movement of the cover is constrained to a plane substantially parallel to the plane of the second opening.

2. Apparatus according to claim 1, wherein the first opening is defined in a first wall of the chamber and the second opening is defined in a second wall of the chamber.

3. Apparatus according to claim 1 or claim 2 wherein the first opening extends over substantially the entire interior surface of the first wall of the chamber and wherein the second opening extends over substantially the entire interior surface of the second wall of the chamber.

4. Apparatus according to any preceding claim, wherein the first opening is opposite the second opening.

5. Apparatus according to any preceding claim, wherein the first opening andthe second opening share a common axis.

6. Apparatus according to any preceding claim, wherein the press comprises a plunger having a first face corresponding substantially to the shape of the first opening.

7. Apparatus according to any preceding claim, wherein the press comprises at least one ram, preferably at least one hydraulic ram.

8. Apparatus according to any preceding claim, wherein the press is configured to apply a compressive force of from 50 to 300 tonnes per square metre, more preferably from 75 to 250 tonnes per square metre, most preferably from 100 to 200 tonnes per square meter.

9. Apparatus according to any preceding claim, further comprising a control system, configured to operate the press to close the first opening and / or to operate the cover to close the second opening.

10. A method of forming a cob product comprising:providing an enclosed chamber defining an interior volume and having a first opening and a second opening;operating a press to close the first opening;loading a cob mix into the interior volume of the chamber;extending a cover in a plane parallel to the plane of the second opening to close the second opening; andoperating the press to apply a compressive force to the interior volume of the chamber to form a cob product.

11. The method according to claim 10, wherein the cover is retracted in a plane parallel to the plane of the second opening to open the second opening, and the press is operated to expel the cob product from the chamber, via the second opening.

12. A method of manufacturing a cob product comprising:preparing a wet cob mix comprising a soil, a fibrous organic material, and water;maturing the wet cob mix for a period of time to reduce its water content;compressing the matured cob mix to form a cob product using apparatusaccording to any of claims 1 to 9 or according to the method of claim 10 or claim 11; andcuring the cob product by drying.

13. The method according to claim 12, wherein, during maturation, the water content of the wet cob mix decreases by at least 30%.

14. The method according to claim 12 or claim 13, wherein, during maturation, the water content of the wet cob mix decreases by up to 80%.

15. The method according to any of claims 12 to 14, wherein the wet cob mix is matured for a period of time of at least 1 day.

16. The method according to any of claims 12 to 15, wherein the wet cob mix is matured for a period of time of up to 14 days.

17. The method according to any of claims 12 to 16, wherein the volume of the matured cob mix decreases by at least 30% when the matured cob mix is compressed.

18. The method according to any of claims 12 to 17, wherein the cob product is cured by drying for at least 1 week.

19. The method according to any of claims 12 to 18, wherein the cob product is cured by drying for up to 10 weeks.

20. A cob product manufactured using apparatus according to any of claims 1 to 9 or according to the methods of any of claims 10 to 19.

21. A cob structure comprising a plurality of cob products manufactured using apparatus according to any of claims 1 to 9 or according to the methods of any of claims 10 to 19.

22. A cob structure according to claim 21, wherein the structure is a cavity wall.

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