Microorganism Loaded Aggregate and Manufacturing Methods

Smart overview of the Invention

The patent application outlines innovative compositions, tools, and methods for creating construction materials infused with microorganisms. These materials can be used for masonry, solid structures, and even for dust control. The process involves applying pigments to aggregate materials such as crushed rock or sand, followed by incubating the pigmented aggregate with urease-producing microorganisms and a nitrogen source like urea, along with a calcium source. This combination facilitates the formation of calcite bridges that enhance the integrity of the aggregate particles.

Manufacturing Process

The manufacturing method described allows for the production of pigmented solid structures that mimic natural stones like granite and marble. By selecting appropriate aggregates and pigments, the process can yield various construction materials, including bricks and counter-tops. Additionally, compositions featuring microorganisms can be packaged into kits for easy integration with most aggregate materials, promoting versatility in construction applications.

Background Context

Current methods for producing colored cement often involve adding pigments to uncolored cement, which can lead to issues such as pigment leaching during hydration and color inconsistencies between batches. Existing products like COLORQUARTZ have limitations in achieving uniform color distribution within cement compositions. The invention addresses these challenges by fixing pigments to solids rather than relying on dispersion, thus enhancing color stability and longevity.

Solid Structures and Their Properties

The application emphasizes that the resulting pigmented solid structures do not leach pigments when exposed to environmental conditions over extended periods, potentially exceeding ten years. These structures can replicate the appearance of various natural materials while maintaining their color integrity. The incorporation of fibers or nanofibers further strengthens these solid forms, ensuring durability in construction applications.

Kits for Colorful Masonry Production

Kits designed for manufacturing pigmented masonry forms are also detailed within the application. These kits typically include urease-producing microorganisms and pigments, potentially combined with activating agents and nutrient media. This innovative approach simplifies the process of creating colorful construction materials while ensuring that the end products are environmentally resilient and visually appealing.