Methods for the manufacture of colorfast masonry
First Claim
1. A method for manufacture of pigmented masonry comprising:
- combining a pigment with particles of an aggregate material to form a mixture, wherein the mixture contains 5% or less of water by weight;
agitating the mixture to disburse the pigment over surfaces of the particles;
adding 1% or less of water by weight and continuing agitating the mixture;
combining the pigment and the particles with urease enzyme or urease-producing cells or spores, nutrients, a calcium source and a nitrogen source to form a composition;
incubating the composition at ambient temperature for a period of time to form calcium carbonate, whereby the calcium carbonate affixes the pigment to the particles of aggregate material; and
forming the pigmented masonry.
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Accused Products
Abstract
The invention is directed to compositions and methods for the manufacture of pigmented solids structures for which can be used for construction and/or decoration. Manufacturing comprises fixing one or more pigments to an aggregate material such as crushed rock, stone or sand. The pigmented aggregate is incubated with urease or urease producing microorganisms, an amount of a nitrogen source such as urea, and an amount of calcium source such as calcium chloride forming calcite bridges between particles of aggregate. The resulting solid has a hardness and colorfastness for most any construction material. Using selected aggregate and pigment, the process also provides for the manufacture of simulated-stone materials such as clay or granite bricks or blocks, marble counter-tops, and more. The invention is also directed to composition containing microorganisms and pigment as kits that can be added to most any aggregate materials.
26 Citations
25 Claims
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1. A method for manufacture of pigmented masonry comprising:
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combining a pigment with particles of an aggregate material to form a mixture, wherein the mixture contains 5% or less of water by weight; agitating the mixture to disburse the pigment over surfaces of the particles; adding 1% or less of water by weight and continuing agitating the mixture; combining the pigment and the particles with urease enzyme or urease-producing cells or spores, nutrients, a calcium source and a nitrogen source to form a composition; incubating the composition at ambient temperature for a period of time to form calcium carbonate, whereby the calcium carbonate affixes the pigment to the particles of aggregate material; and forming the pigmented masonry. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A method of manufacture of simulated-stone masonry comprising:
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combining a pigment with particles of an aggregate material to form a mixture wherein the mixture contains 5% or less of water by weight; agitating the mixture to disburse the pigment over surfaces of the particles; adding 1% of water to the mixture and continue agitating the mixture; combining the pigmented particles with urease enzyme or urease-producing cells or spores, nutrients, a calcium source and a nitrogen source to form a composition; adding one or more additional pigments to the surface of the composition; incubating the composition for a period of time to form calcium carbonate; forming the simulated-stone masonry. - View Dependent Claims (15, 16, 17)
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18. A method of manufacturing a pigmented masonry comprising:
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mixing a combination of at least one pigment and particles of at least one aggregate material with urease and/or urease-producing cells or spores, water, nutrients, a calcium source and a nitrogen source; depositing or extruding the mixture into a form; and incubating the mixture for a period of time to allow the formation of covalent bonds between the particles, wherein the covalent bonds affix the at least one pigment to surfaces of the particles; and forming the pigmented masonry. - View Dependent Claims (19, 20, 21, 22, 23, 24, 25)
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Specification