US-20260124650-A1 - Waste Treatment System

US20260124650A1US 20260124650 A1US20260124650 A1US 20260124650A1US-20260124650-A1

Abstract

A waste treatment system is provided. The waste treatment system includes an industrial shredder that processes non-recyclable waste into fine, sprayable material, an ultraviolet sterilizer that sanitizes the shredded waste material, and hydraulic rams that compress the material into solid construction blocks that secure to one another. The waste material is hydraulically compressed into a modular mold system that allows the production of blocks in various sizes. The blocks are reinforced with vertical bars and spacer rods, ensuring structural integrity. A male snap cap is secured to a first end of the bar and a female snap structure is secured to an opposing second end of the bar. The female snap structures are recessed at the bottom of each block to interlock securely with the male snap caps. The waste treatment system effectively reduces landfill waste and carbon footprint by converting waste into reusable construction materials.

Inventors

Cory Fletcher

Assignees

Cory Fletcher

Dates

Publication Date: 20260507
Application Date: 20241101

Claims (20)

1 ) A waste treatment system, comprising: a shredder configured to process waste into a sprayable consistency, defined as having an average particle diameter of less than 2 millimeters; an ultraviolet sterilizer configured to receive and sanitize the processed waste; a modular mold system having a mold compaction head and a plurality of walls, wherein a hydraulic ram is connected to the mold compaction head and the plurality of walls configured to compress the sterilized waste into a block; a bar having a first end and an opposing second end, wherein the bar is integrated into the block; a female snap structure disposed on the first end of the bar and recessed within a lower side of the block; a male snap cap disposed on the second end of the bar, wherein the male snap cap is exterior to an upper side of the block; wherein the female snap structure of the block is configured to receive a male snap cap of a second block and the male snap cap of the block is configured to insert into a female snap structure of a third block.
2 ) The waste treatment system of claim 1 , wherein the industrial shredder includes multiple stages to progressively reduce the particle size of the waste to the sprayable consistency, wherein each stage comprises a different sized blade.
3 ) The waste treatment system of claim 1 , wherein the ultraviolet sterilizer is configured to achieve sterilization of the waste material prior to compaction.
4 ) The waste treatment system of claim 1 , wherein the hydraulic ram exerts a pressure in excess of 10 gigatons configured to prevent an internal cavity larger than 0.1 millimeters in diameter.
5 ) The waste treatment system of claim 1 , further comprising a spray injection nozzle for coating the block with a protective layer configured to waterproof the block.
6 ) The waste treatment system of claim 5 , wherein the protective layer is composed of a uniform coat of Duayen™.
7 ) The waste treatment system of claim 1 , wherein mold compaction head and the plurality of walls are independent from one another, allowing each of the plurality of walls to be interchanged with a different sized wall.
8 ) The waste treatment system of claim 7 , wherein the modular mold system is configured to produce a block in various sizes ranging from 6″×6″×6″ to 48″×96″×48″.
9 ) The waste treatment system of claim 1 , wherein the waste treatment system is powered by an electromagnetic generator.
10 ) The waste treatment system of claim 1 , further comprising a spacer rod disposed perpendicularly between a pair of adjacent bars.
11 ) The waste treatment system of claim 1 , further comprising a precision torque motor for the installation of the male snap cap on the block.
12 ) The waste treatment system of claim 11 , wherein the precision torque motor is configured to thread the male snap cap onto each block.
13 ) The waste treatment system of claim 1 , wherein the male snap cap comprises a male cap member and a mating member, the male cap member having an aperture disposed on a lower side thereof for threadedly engaging with the bar and the mating member extending from an upper side of the male cap member configured to insert within a mating recess of the female snap structure.
14 ) The waste treatment system of claim 13 , wherein the mating member comprises a smaller diameter than a diameter of the male cap member.
15 ) The waste treatment system of claim 13 , wherein the female snap structure comprises a female cap member and a female mating member, the female cap member having an aperture disposed on an upper side thereof for threadedly engaging with the bar and the female mating member having the mating recess.
16 ) The waste treatment system of claim 15 , wherein the female mating member extends from a lower side of the female cap structure and the mating recess is disposed on a lower side of the female mating member.
17 ) The waste treatment system of claim 16 , a lowermost portion of the female snap structure is flush with the bottom of the block.
18 ) A block produced by the process comprising: processing waste into a sprayable consistency, defined as having an average particle diameter of less than 2 millimeters, using a shredder; sanitizing the processed waste using an ultraviolet sterilizer; compressing the sterilized waste into a block using a modular mold system, wherein the mold system includes a mold compaction head and a plurality of walls, and a hydraulic ram connected to the mold compaction head; integrating a bar into the block, wherein the bar has a first end and an opposing second end; disposing a female snap structure on the first end of the bar and recessing it within a lower side of the block; disposing a male snap cap on the second end of the bar, wherein the male snap cap is exterior to an upper side of the block; wherein the female snap structure of the block is configured to receive a male snap cap of a second block, and the male snap cap of the block is configured to insert into a female snap structure of a third block.
19 ) The block of claim 18 , wherein the mold compaction head and the plurality of walls are independent from one another, allowing each of the plurality of walls to be interchanged with different sized walls.
20 ) The block of claim 1 , further comprising a spacer rod disposed perpendicularly between a pair of adjacent bars.

Description

BACKGROUND OF THE INVENTION The present invention relates to a waste treatment system designed to process non-recyclable waste into reusable construction materials. In the current technological landscape, managing non-recyclable waste is a significant challenge, with landfills and dumps accumulating vast amounts of waste that contribute to environmental degradation and carbon emissions. Existing waste management solutions, such as incineration and traditional landfilling, come with numerous drawbacks, including harmful emissions, inefficient use of space, and limited ability to repurpose the waste into useful products. One existing method for dealing with waste involves shredding and compacting waste materials into bales for disposal or limited recycling applications. However, this approach often fails to produce materials that are versatile or structurally sound enough for construction purposes. The bales are usually bulky, prone to decomposition, and not suitable for long-term structural use. Moreover, the process of creating these bales does not adequately address the sterilization of waste, leading to potential health hazards and environmental contamination. Another alternative involves the use of waste-to-energy plants, where non-recyclable waste is incinerated to produce energy. While this method reduces the volume of waste, it generates significant greenhouse gas emissions and toxic byproducts that require careful management. Additionally, waste-to-energy plants are expensive to build and operate, and they often face public opposition due to concerns about air pollution and health risks. In the context of construction materials, current options such as concrete blocks, bricks, and prefabricated panels are primarily made from natural resources like sand, gravel, and clay. These materials require substantial energy and resources to produce, contributing to environmental degradation. Furthermore, the increasing demand for sustainable construction materials highlights the need for innovative solutions that can reduce reliance on virgin materials and minimize environmental impact. Therefore, there exists a need for a system configured to transform non-recyclable waste into high-quality construction blocks. By converting waste into reusable construction materials, the waste treatment system significantly reduces the volume of waste sent to landfills, mitigates the environmental impact of traditional waste management practices, and provides a sustainable alternative to conventional building materials. This system not only addresses the pressing issue of waste management but also contributes to the development of sustainable construction practices, aligning with global efforts to reduce carbon footprints and promote environmental stewardship. In light of the systems and methods disclosed in the known art, it is submitted that the present invention substantially diverges in design elements and methods from the known art and consequently it is clear that there is a need in the art for an improvement in waste treatment systems. In this regard the instant invention substantially fulfills these needs. SUMMARY OF THE INVENTION In view of the foregoing disadvantages inherent in the known systems for waste treatment now present in the known art, the present invention provides a waste treatment system that converts waste into reusable construction materials. It is an objective of the present invention to provide an embodiment of the waste treatment system that processes waste through a multistage industrial shredder that reduces the material to a fine, sprayable consistency. This fine material is then sterilized using ultraviolet light to ensure it is safe for handling and use. The sterilized waste is compacted into solid blocks using hydraulic rams capable of exerting pressure in excess of 10 gigatons, resulting in substantially voidless, blocks. Voidless herein refers to a state where the material, when pressed by a 10 gigaton hydraulic ram, is compacted to such a degree that it contains no air pockets, gaps, or internal cavities larger than 0.1 millimeters in diameter. This ensures uniform density and structural integrity throughout the entire block, enhancing its strength and durability for construction purposes. It is another objective of the present invention to provide an embodiment of the waste treatment system comprising a modular mold setup that allows the production of blocks in various sizes, by changing a mold in the hydraulic press. Each block is reinforced with vertical round bars made of stainless steel, aluminum, or titanium, depending on the required load capacity. This reinforcement ensures the blocks are suitable for a wide range of construction applications, from temporary structures to permanent buildings. It is another objective of the present invention to provide an embodiment of the waste treatment system comprising spray injection nozzles that coat each block with a protective layer of Duaye