Bio-aggregate-based building material

Abstract

To provide a bio-based building material.SOLUTION: A bio-aggregate-based building material is provided that includes a macro-porous element formed from a mixture of a calcium-carbonate-derived binder and a lignocellulose bio-aggregate. The macro-porous element has an open matrix for air and / or vapor and / or water, in which a micro-capillary structure is formed by the lignocellulose bio-aggregate. A porosity of the macro-porous element is at least 50% of a bulk volume of the building material. Bio-aggregate granulates of 40 wt.% to 80 wt.% that form the lignocellulose bio-aggregate have a maximum particle size falling within a lower 50% of a particle size range. Bio-aggregate granulates of 5 wt.% or less that form the lignocellulose bio-aggregate have a maximum particle size falling within an upper 20% of the particle size range.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a bioaggregate-based building material formed from a mixture of lignocellulosic bioaggregate and a calcium carbonate-derived binder, and a method for producing the bioaggregate-based building material. [Background technology]

[0002] Growing awareness of climate change has led many governments to strive to achieve the UN IPCC's goal of achieving net-zero carbon emissions by 2050 to avoid a 1.5°C increase in global warming.

[0003] In 2009, construction was found to be responsible for generating 23% of the world's total carbon emissions. Emerging countries such as China were found to be responsible for generating the majority of these emissions (estimated at 60%) (Huang et al., 2018). A 2012 World Bank report indicated that the global construction industry is responsible for more than half of the planet's solid waste. By 2021, it is predicted that 1.3 billion tons of solid waste will be generated annually, and this is estimated to increase to 2.2 billion tons per year by 2025.

[0004] With a growing global population and rapid urbanization, creating a decarbonized environment will be a key focus as governments aim to reduce carbon emissions to net-zero within the next 30 years. The majority of energy used in buildings, whether residential or commercial, is consumed according to heating space requirements. Improving the energy efficiency of buildings is a sure way to ensure that the expected expansion of building area does not directly translate into increased energy consumption (International Energy Agency 2018).

[0005] Bio-based building materials offer the building industry an opportunity to decarbonize the production, use, and waste disposal of materials widely used within the industry. To date, the use of bio-based materials in building materials as a replacement for traditional building materials has been limited due to their mechanical properties. Furthermore, bio-based materials are more variable than synthetic or inorganic materials. Thus, on-site or in-situ manufacturing and casting of bio-based composites can result in greater variability in the physical properties of these materials. Bio-based materials have greater natural variability because they are grown externally in uncontrolled environments, exposed to seasonal fluctuations, and further variability in unknown climate changes. While there has been some adoption of bio-based building materials in the building industry, they have not been widely adopted by the mainstream building industry. Reducing performance variability through mass production in controlled environments and smart manufacturing that takes variability into account could enable further adoption of bio-based materials in the building industry. Traditional building materials are very well constructed, driving down costs with large-scale capital infrastructure manufacturing facilities. These well-constructed materials are also becoming standardized globally.

[0006] It is estimated that people spend 90% of their lives indoors. The humidity of indoor environments often changes between day and night. High humidity increases the rate of heat transfer from the skin, making the environment feel colder. As a result, users may turn up the heating indoors to increase the environmental temperature. However, higher thermal comfort can be achieved in environments that are less sensitive to excessive relative humidity. Controlled relative humidity within buildings can achieve higher thermal comfort at lower temperatures, requiring less energy input. Furthermore, indoor environments are prone to condensation, which can create favorable conditions for the development of pathogens or mold that can cause respiratory diseases such as asthma.

[0007] Pressures on the gypsum industry are also increasing. Gypsum production is linked to coal production. Gypsum is mined and found in seams adjacent to coal. However, naturally mined gypsum is known to have lower purity levels. Synthetic gypsum, popular in the creation of gypsum board, is extracted from flue gases in coal-fired power plants. Many countries are targeting a transition away from coal-fired power generation. As a result, synthetic gypsum sources are beginning to dwindle. In addition, disposal of gypsum board is restricted and comes with associated costs. When gypsum decays in the presence of organic matter, it releases sulfur dioxide, a toxic and explosive gas. Therefore, gypsum board is a controlled waste stream and is disposed of in "single-cell" landfills, although installing a dry lining has associated costs.

[0008] Therefore, there is a need for bio-based building materials, e.g., non-gypsum bio-based materials, that have mechanical properties that are at least comparable to those of conventional building materials, e.g., at least comparable flexural fracture strength. There is a need for cost-effective and environmentally friendly bio-based building materials that have reduced production costs and reduced disposal costs compared to conventional building materials. There is a need for bio-based building materials with less variability in physical properties. There is a need for bio-based building materials that are suitable for large-scale manufacturing. There is a need for bio-based building materials that allow humidity control. For example, there is a need for bio-based building materials, e.g., bio-based boards that are easy to install, breathable building materials such as interior lining materials, etc. Summary of the Invention [Means for solving the problem]

[0009] According to a first aspect of the present invention, A bioaggregate-based building material, a macroporous element formed from a mixture of a calcium carbonate-derived binder and lignocellulosic bioaggregates, the macroporous element having an open matrix to air, steam, and / or water, with microcapillary structures formed by the lignocellulosic bioaggregates; The porosity of the macroporous element is at least 50% of the bulk volume of the building material; Between 40% and 80% by weight of the bioaggregate particulates forming the lignocellulosic bioaggregate have a maximum particle size that falls within the lower 50% of the particle size range; Up to 5% by weight of the bioaggregate particulates forming the lignocellulosic bioaggregate provide the bioaggregate-based building material with a maximum particle size that falls within the upper 20% of the particle size range.

[0010] According to a second aspect of the present invention, 1. A method of forming a building material as described herein comprising macroporous elements with a microcapillary structure and an open matrix to air and / or steam and / or water, comprising: mixing lignocellulosic bioaggregates with a calcium carbonate-derived binder, wherein between 40% and 80% by weight of the bioaggregate particulates forming the lignocellulosic bioaggregates have a maximum particle size that falls within the lower 50% of the particle size range; The method provides for 5% by weight or less of the bioaggregate particulates forming the lignocellulosic bioaggregate to have a maximum particle size that falls within the upper 20% of the particle size range.

[0011] Once the mixture of bio-aggregates and calcium carbonate-derived binder is produced, the mixture may be cured. The curing step may occur at any suitable temperature and for any suitable period of time.

[0012] According to a third aspect of the present invention, there is provided a kit of parts forming a building material comprising a macroporous element having an open matrix to air and / or steam and / or water, with a microcapillary structure as described herein, comprising: a lignocellulosic bioaggregate, wherein between 40% and 80% by weight of the bioaggregate particulates forming the lignocellulosic bioaggregate have a maximum particle size that falls within the lower 50% of the particle size range; 5% or less by weight of the bioaggregate particulates forming the lignocellulosic bioaggregate are lignocellulosic bioaggregates having a maximum particle size within the upper 20% of the particle size range; a calcium carbonate-derived binder; Optionally, further: at least one rheological agent; at least one humectant, Fiber reinforcement, at least one flocculant; A kit is provided that includes one or more of the at least one cementitious binder.

[0013] The present invention provides bioaggregate-based building materials with high porosity, low density, high breathability, high water vapor permeability, high water vapor buffering capacity, and good thermal insulation properties. The bioaggregate building materials of the present invention have been shown to be breathable (i.e., to allow water vapor-carrying air to flow in and out of the building material) and to regulate humidity conditions in an environment. The bioaggregate building materials of the present invention have been shown to have improved thermal and hygrothermal properties. The bioaggregate building materials of the present invention have been shown to have improved acoustic properties. The bioaggregate building materials of the present invention have also been shown to sequester volatile organic compounds.

[0014] The term "bioaggregate" is used herein to refer to particulates formed from plant material. Each particulate within a bioaggregate has a maximum particle size, which is used herein to refer to the particle's largest dimension. Each particulate retains the microcapillary structure present in the original plant material.

[0015] Lignocellulosic bioaggregates are composed of cellulose, hemicellulose, and lignin, and their presence in a mixture has been shown to improve the moisture absorption properties of the resulting building material.

[0016] The calcium carbonate-derived binder, together with the lignocellulosic bio-aggregate, forms an open matrix to air, and / or steam, and / or water within the resulting bio-aggregate building material that provides the necessary structural integrity to the bio-aggregate building material while also providing a bio-aggregate building material that is suitable for mass production.

[0017] After being mined, calcium carbonate is burned, chemically releasing carbon dioxide and calcium oxide, which can be slaked to form calcium hydroxide or calcium hydrate. Impurities in calcium carbonate can also lead to the formation of materials with other terminologies, but impurities in calcium oxide can increase the hydraulic properties of the binder, which is often also referred to as natural hydraulic lime. The term "calcium carbonate-derived binder" is used herein to encompass all of these binders.

[0018] The term "open matrix to air and / or steam and / or water" means It is used herein to refer to a matrix configured to allow the passage of air and / or water vapor and / or water into and out of the matrix, eg, through the matrix.

[0019] Lignocellulosic bioaggregates consist of elongated, hollow xylem cells. The xylem cells of lignocellulosic bioaggregates are responsible for providing the bioaggregates with a highly anisotropic microcapillary structure. Hydroxyl bridges and / or hydrogen bonds can form between calcium carbonate-derived binders and lignocellulosic bioaggregate particles, providing adhesion between the binder and the bioaggregates within the mixture. Once cured, the lignocellulosic bioaggregates and calcium carbonate together form a bio-based building material with a macroporous element that has a microcapillary structure and an open matrix to air, steam, and / or water.

[0020] The macroporous element of the product comprises a plurality of voids. The porosity of the macroporous element is defined by the void fraction of the macroporous element. The porosity of the macroporous element of the building material is preferably at least 50%, preferably at least 60%, preferably at least 70%, e.g., at least 80%, as a percentage of the bulk volume of the building material.

[0021] The voids within the macroporous elements may be closed or open and connected to other voids, and / or the exterior surface of the building material may be formed by a microcapillary structure formed by the lignocellulosic bioaggregates, allowing air and / or water vapor and / or water to be absorbed and released by the product through the microcapillary structure of capillary flow. The microcapillaries within the microcapillary structure of the bioaggregates may have different rates of capillary adsorption relative to the macroporous elements. In this way, the microcapillaries within the matrix may allow the building material to absorb water vapor and / or water and / or air into the macroporous elements (or voids) at different rates, thereby providing the building material with increased breathability, increased porosity, and / or increased water vapor and / or water absorption capacity.

[0022] During use, at high humidity, water vapor passes through the microcapillaries provided within the macroporous element of the product and can be collected within the pores within the macroporous element. Under lower humidity conditions, the water vapor stored within the pores of the macroporous element can be released from the product back into the environment. In this way, the building material of the present invention can regulate its internal relative humidity by buffering water vapor through continuous cycles of absorbing and releasing water vapor to and from the environment.

[0023] The macroporous elements with voids and microcapillary structures allow air to flow in and out of the open matrix, which provides the breathable quality of the building material. The breathability of the building material of the present invention ensures a significant reduction in the risk of mold and condensation in the environment associated with the building material. As a result, the building material of the present invention helps to reduce the risk of respiratory diseases and creates a healthier environment for building occupants.

[0024] The bioaggregate-based building material of the present invention is preferably composed of natural materials. Preferably, the bioaggregate-based building material is composed of at least 80% by weight, preferably at least 90% by weight, preferably at least 95% by weight, for example about 99% by weight, of natural materials relative to the total weight of the mixture. In one embodiment, the bioaggregate-based building material is composed entirely of natural materials.

[0025] In one embodiment, the bioaggregate-based building material is biodegradable, preferably at least 10% by weight, preferably at least 20% by weight, preferably at least 30% by weight of the material is biodegradable, based on the total weight of the mixture forming the product, preferably up to 90% by weight, preferably up to 80% by weight, based on the total weight of the mixture forming the product. Preferably, 70% or less by weight of the material is biodegradable. Preferably, between 10% and 90% by weight, preferably between 20% and 80% by weight, preferably between 30% and 70% by weight, for example between 45% and 65% by weight, of the material is biodegradable, based on the total weight of the mixture forming the product. In one embodiment, the bioaggregate-based building material is entirely composed of biodegradable materials. Thus, the bioaggregate-based building material is biodegradable and can be broken down into natural materials in the environment without producing any harmful by-products or toxins. Because the bioaggregate-based building material decomposes into the organic layer of the soil, the bioaggregate-based building material offers agronomic advantages over conventional building materials.

[0026] In one embodiment, a bioaggregate-based building material can be substantially free of gypsum. The term "substantially free" is used herein to describe a product containing 1% or less by weight, preferably 0.5% or less, preferably 0.2% or less, preferably 0.1% or less by weight, and preferably 0% by weight, of gypsum, based on the total weight of the mixture. In one embodiment, the present invention provides a gypsum-free bioaggregate-based building material with structural properties comparable to conventional building materials. The present invention provides a gypsum-free building material without the problems associated with the use of gypsum, such as problems associated with dwindling gypsum sources, the reduced purity of naturally mined gypsum, the increased costs associated with extraction and calcination, the dwindling sources of synthetic gypsum, and problems associated with the disposal of gypsum treated as controlled waste.

[0027] The lignocellulosic bioaggregates of the product of the present invention are preferably renewable annually, thereby reducing the need for finite materials such as gypsum sources.

[0028] Lignocellulosic bioaggregates may be provided by a wide range of plant species, and thus building materials may be prepared from low-cost, readily (and preferably locally) available, and abundant plant material. Furthermore, building materials of the present invention may be produced at low cost and on a large scale due to low associated energy costs.

[0029] Examples of plant materials suitable for use as lignocellulosic bioaggregates include perennial plants, such as processed perennials, and / or by-products of perennial processing, having a suitable lignocellulosic profile. For example, if perennials deemed suitable are processed, these treated perennials may be incorporated as lignocellulosic bioaggregates for agricultural benefits. If the by-products of perennial processing have the correct lignocellulosic profile, these by-products may be incorporated as lignocellulosic bioaggregates. Plant materials suitable for use as bioaggregates include both softwood and hardwood wood particles with the appropriate particle size and suitable cellular structure.

[0030] Examples of plant species with cell-capillary architecture suitable for use as bioaggregates include, but are not limited to, woody lignin-based plants.

[0031] In one embodiment, the bioaggregate comprises one or more of common wheat (Triticum aestivum), hemp (Cannabis sative), oat (Avena sativa), rapeseed (Brassica napus), barley (Hordeum vulgare), Japanese silvergrass (Miscanthus giganteus), bamboo, flax, rice straw, corn straw, sugarcane bagasse, sisal straw, or any combination thereof.

[0032] The bioaggregates may be formed from any suitable part of the plant. Preferably, the bioaggregates are formed from the stem of the plant. The plant, or plant part, is mechanically treated to separate the non-lignocellulosic portions of the plant material prior to the formation of the bioaggregates. It may be removed.

[0033] The bioaggregate-based building material preferably comprises comminuted lignocellulosic bioaggregates. The comminuted lignocellulosic bioaggregates preferably retain the microcapillary structure of the lignocellulosic bioaggregates. The comminuted lignocellulosic bioaggregates are preferably in the form of straw-like lignocellulosic material, such as finely particulated straw-like lignocellulosic material. The lignocellulosic bioaggregates may be comminuted using any conventional comminution mechanism, such as a knife, hammer, rotary, or ball mill. The comminuted lignocellulosic bioaggregates may be passed through a screen or sieve with predetermined apertures to allow comminuted lignocellulosic bioaggregates having predetermined dimensions to pass through.

[0034] The bioaggregates are preferably formed from chemically untreated lignocellulosic plant material, the term "chemically untreated" being used herein to describe plant material in which the cellular capillary architecture within the plant material remains unchanged.

[0035] Bioaggregates may be formed from any suitable plant species having a suitable cell-capillary architecture, such as an open tubular cell-capillary structure, and a suitable ratio of lignin to cellulose within the plant material. Preferably, the ratio of lignin to cellulose within the bioaggregate is 3:1 or less, preferably 2.5:1 or less, preferably 2:1 or less, e.g., about 1.6:1. Preferably, the ratio of lignin to cellulose within the bioaggregate is at least 0.3:1, preferably at least 0.4:1, preferably at least 0.5:1, e.g., about 0.6:1. Preferably, the ratio of lignin to cellulose within the bioaggregate is within the range of between 0.3:1 and 3:1, preferably between 0.4:1 and 2.5:1, preferably between 0.5:1 and 2:1, preferably between 0.6:1 and 1.6.

[0036] The structure of the macroporous elements of the matrix has been shown to be highly resistant to the continuous circulation of water vapor without degradation. Therefore, the building material of the present invention can continuously absorb and release water / water vapor without signs of degradation. This extends the lifespan of the building material of the present invention. The cell capillary structure and chemical composition of the lignocellulose bioaggregates have been shown to be responsible for the material properties of this building material. The microfibers within plant materials are highly cellulose-derived and are responsible for water transport. To protect the microfibers from degradation, they are surrounded by hydrophilic compounds, such as lignin and hemicellulose. Lignin has been shown to be more resistant to degradation from contact with water than cellulose. Thus, the presence of lignocellulose bioaggregates within the building material helps ensure that the product can withstand the continuous circulation of water vapor without degradation.

[0037] The maximum bioaggregate particle size of the particulate matter within the bioaggregate is selected to ensure that the product has an open matrix configured to allow for the absorption / release of air and / or water and / or water vapor, as discussed herein, and so that the building material can be produced on a large scale, for example using industrial processes.

[0038] In particular, the maximum bioaggregate particle size, and in particular the range of maximum bioaggregate particle sizes within the bioaggregate, may be selected to provide a mixture of calcium carbonate derived binder and bioaggregate with suitable wetting flow kinetics, viscosity, rheology, and cohesion that is amenable to industrial processing such as extrusion, e.g., continuous extrusion, deposition, e.g., 3D printing.

[0039] The maximum particle size of the particulate matter in the bioaggregate is preferably about 100 mm or less, more preferably about 70 mm or less, more preferably about 50 mm or less, more preferably 40 mm or less, for example 30 mm or less.

[0040] The maximum particle size of the bioaggregate particulates is preferably at least about 0.1 mm, more preferably at least about 0.15 mm, more preferably at least about 0.2 mm, for example at least about 0.25 mm.

[0041] The maximum particle size range of the bioaggregate granules is preferably within the range of 0.1 mm to 100 mm, preferably within the range of 0.1 mm to 70 mm, and preferably within the range of 0.1 mm to 50 mm.

[0042] The maximum particle size distribution profile of the bioaggregate particulates is important to both the manufacturing and structural performance of the resulting product.

[0043] Particle size distribution is conventionally defined by its determination method. One suitable method is sieve analysis, in which powder is separated using sieves of different sizes. Therefore, particle size distribution is determined for a specific size range based on the size of the sieve used. Particle size distribution may be expressed in cumulative form.

[0044] In one embodiment, the bioaggregates have a predetermined particle size distribution ranging from a minimum maximum particle size to a maximum maximum particle size.

[0045] In one embodiment, the cumulative particle size distribution function of the bioaggregates, when determined from the highest maximum particle size to the lowest maximum particle size, has an approximately sigmoidal shape.

[0046] In one embodiment, at least 0.1 wt. %, preferably at least 0.5 wt. %, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the top 10%, preferably the top 20%, preferably the top 30%, preferably the top 40% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates in the bioaggregate).

[0047] In one embodiment, no more than 5% by weight, preferably no more than 2% by weight, for example about 1% by weight, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the top 10%, preferably the top 20%, preferably the top 30%, preferably the top 40%, preferably the top 50% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates in the bioaggregate).

[0048] In one embodiment, between 0.1% and 5% by weight, preferably between 0.1% and 2% by weight, preferably between 0.1% and 1% by weight, for example between 0.5% and 1% by weight, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the top 10%, preferably within the top 20%, preferably within the top 30%, preferably within the top 40% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0049] In one embodiment, substantially 0% by weight, preferably at least 0.1% by weight, preferably at least 0.2% by weight of the bioaggregate particulates forming the bioaggregate are between the top 20% and top 30%, preferably the top 20%, of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates in the bioaggregate). % to have a maximum particle size that falls within the top 40% range.

[0050] In one embodiment, no more than 2% by weight, preferably no more than 1% by weight, preferably no more than 0.5% by weight of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the top 20% to top 30%, preferably between the top 20% to top 40% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates in the bioaggregate).

[0051] In one embodiment, between 0% and 2% by weight, preferably between 0% and 1% by weight, between 0.1% and 2% by weight, preferably between 0.1% and 1% by weight, preferably between 0.1% and 0.5% by weight of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the top 20% to 30% by weight, preferably the top 20% to 40% by weight of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0052] In one embodiment, at least 10% by weight, preferably at least 15% by weight, preferably at least 20% by weight of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the top 50% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0053] In one embodiment, no more than 50% by weight, preferably no more than 40% by weight, preferably no more than 30% by weight of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the top 50% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0054] In one embodiment, between 10% and 50% by weight, preferably between 10% and 40% by weight, preferably between 10% and 30% by weight, preferably between 15% and 50% by weight, preferably between 15% and 40% by weight, preferably between 15% and 30% by weight, preferably between 20% and 50% by weight, preferably between 20% and 40% by weight, preferably between 20% and 30% by weight, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the top 50% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates in the bioaggregate).

[0055] In one embodiment, at least 0.1 wt. %, preferably at least 0.5 wt. %, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the bottom 5% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates in the bioaggregate).

[0056] In one embodiment, no more than 5% by weight, preferably no more than 2% by weight, for example no more than about 1% by weight, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the bottom 5% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates in the bioaggregate).

[0057] In one embodiment, between 0.1% and 5% by weight, preferably between 0.1% and 2% by weight, preferably between 0.1% and 1% by weight, for example between 0.5% and 1% by weight, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the bottom 5% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates in the bioaggregate).

[0058] In one embodiment, at least 1% by weight, preferably at least 2% by weight, preferably at least 3% by weight of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the bottom 10% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates in the bioaggregate).

[0059] In one embodiment, no more than 15% by weight, preferably no more than 12% by weight, for example no more than about 10% by weight, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the bottom 10% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates in the bioaggregate).

[0060] In one embodiment, between 1% and 15% by weight, preferably between 1% and 10% by weight, preferably between 2% and 10% by weight, for example between 5% and 10% by weight, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the bottom 10% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates in the bioaggregate).

[0061] In one embodiment, at least 2% by weight, preferably at least 5% by weight, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the bottom 20% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0062] In one embodiment, no more than 20% by weight, preferably no more than 15% by weight, no more than 10% by weight of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the bottom 20% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates in the bioaggregate).

[0063] In one embodiment, between 2% and 20% by weight, preferably between 2% and 15% by weight, preferably between 5% and 20% by weight, preferably between 5% and 15% by weight, preferably between 5% and 10% by weight, of the aggregate particulates forming the bioaggregate have a maximum particle size that falls within the bottom 20% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates in the bioaggregate).

[0064] In one embodiment, preferably at least 5% by weight, preferably at least 10% by weight, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the lower 5% to lower 20%, preferably between the lower 10% to lower 20%, of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0065] In one embodiment, no more than 30% by weight, preferably no more than 25% by weight, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the lower 5% to lower 20%, preferably between the lower 10% to lower 20%, of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0066] In one embodiment, between 5% and 30% by weight, preferably between 5% and 25% by weight, preferably between 10% and 30% by weight, preferably between 10% and 25% by weight of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the lower 5% to lower 20% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate), preferably between the lower 10% to lower 20%.

[0067] In one embodiment, at least 10% by weight, preferably at least 15% by weight, preferably at least 20% by weight of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the bottom 30% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0068] In one embodiment, no more than 40% by weight, preferably no more than 30% by weight, preferably no more than 25% by weight of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the bottom 30% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates in the bioaggregate).

[0069] In one embodiment, between 10% and 40% by weight, preferably between 10% and 30% by weight, preferably between 10% and 25% by weight, preferably between 15% and 40% by weight, preferably between 15% and 30% by weight, preferably between 15% and 25% by weight, preferably between 20% and 25% by weight of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the bottom 30% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates in the bioaggregate).

[0070] In one embodiment, at least 5% by weight, preferably at least 8% by weight, preferably at least 10% by weight, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the lower 20% to lower 30% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0071] In one embodiment, no more than 20% by weight, preferably no more than 15% by weight, e.g., about 13% by weight, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the lower 20% to lower 30% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0072] In one embodiment, between 5% and 20% by weight, preferably between 5% and 15% by weight, preferably between 10% and 15% by weight of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within between the bottom 20% and bottom 30% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0073] In one embodiment, at least 20% by weight, preferably at least 30% by weight, preferably at least 40% by weight of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the bottom 40% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0074] In one embodiment, no more than 70% by weight, preferably no more than 60% by weight, preferably no more than 55% by weight, preferably no more than 50% by weight of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the bottom 40% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0075] In one embodiment, between 20% and 70% by weight, preferably between 30% and 70% by weight, preferably between 30% and 60% by weight, preferably between 40% and 60% by weight, preferably between 30% and 50% by weight, preferably between 20% and 70% by weight, preferably between 30% and 70% by weight, preferably between 30% and 60% by weight, preferably between 40% and 60% by weight, preferably between 30% and 50% by weight, Between 40% and 50% by weight of the bioaggregate particulates have a maximum particle size that falls within the bottom 40% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates in the bioaggregate).

[0076] In one embodiment, at least 10% by weight, preferably at least 15% by weight, preferably at least 20% by weight of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the lower 30% to lower 40% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0077] In one embodiment, no more than 40% by weight, preferably no more than 30% by weight, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the lower 30% to lower 40% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0078] In one embodiment, between 10% and 40% by weight, preferably between 10% and 30% by weight, preferably between 15% and 40% by weight, preferably between 15% and 30% by weight, preferably between 20% and 40% by weight, preferably between 20% and 30% by weight of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the lower 30% to lower 40% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0079] In one embodiment, at least 40% by weight, preferably at least 50% by weight, preferably at least 60% by weight of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the bottom 50% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0080] In one embodiment, no more than 80% by weight, preferably no more than 70% by weight, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the bottom 50% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0081] In one embodiment, between 40% and 80% by weight, preferably between 50% and 80% by weight, preferably between 60% and 80% by weight, preferably between 40% and 70% by weight, preferably between 50% and 70% by weight, preferably between 60% and 70% by weight, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the bottom 50% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates in the bioaggregate).

[0082] In one embodiment, at least 5% by weight, preferably at least 10% by weight, preferably at least 15% by weight, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the lower 40% to lower 50% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0083] In one embodiment, no more than 30% by weight, preferably no more than 20% by weight, of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within the lower 40% to lower 50% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0084] In one embodiment, between 5% and 30% by weight, preferably between 5% and 20% by weight, preferably between 10% and 20% by weight of the bioaggregate particulates forming the bioaggregate have a maximum particle size that falls within between the lower 40% and lower 50% of the particle size range (measured from the lowest maximum particle size to the highest maximum particle size of the particulates within the bioaggregate).

[0085] The greater the thickness of the building material, the greater the proportion of bending stiffness that can be obtained from the product morphology. This therefore allows for the formation of larger products, such as thicker, from bioaggregates with larger maximum particle sizes, rather than being suitable for smaller construction dimensions. The distribution of maximum particle size within the bioaggregates and the relationship between different particle size fractions of the particulate matter can be measured by the thickness, i.e., particle size, of the product.

[0086] It is understood that the maximum particle size of the particulate matter in the bioaggregate may depend on the dimensions of the resulting building material. For example, the maximum particle size of the particulate matter in the bioaggregate may be 0.5 times or less, preferably 0.4 times or less, and preferably 0.3 times or less, the dimension of the building material, e.g., the thickness of the building material. For example, a building material such as an insulation panel may have a thickness of, for example, up to 200 mm, and the maximum particle size of the bioaggregate present in the building material may be 70 mm.

[0087] It is understood that as the maximum particle size of the particulates within the bio-aggregate scales up, the distribution of smaller particulates within the bio-aggregate follows. The range of maximum particle sizes of the particulates within the bio-aggregate provides a highly cohesive mixed material that allows the bio-aggregate and the mixture of bio-aggregates and binder to flow well during industrial manufacturing and provides a material architecture with enhanced structural efficiency.

[0088] Furthermore, it has been found that the products of the present invention have improved heat resistance compared to conventional building materials. The bioaggregate-based building materials of the present invention are configured to store air within the voids and microcapillaries of the open matrix of the macroporous elements. In this manner, the air-filled (or partially filled) voids and / or microcapillaries reduce the heat transfer properties of the products, which have improved heat resistance compared to conventional building materials. It has also been found that the thermal and hygrothermal properties of building materials can be optimized by using bioaggregates with granules having a larger maximum particle size. The maximum particle size of the granules in the bioaggregates forming the building material may be selected to optimize the thermal and hygrothermal properties of the resulting building material.

[0089] The products of the present invention have also been found to have improved acoustic performance compared to conventional building materials. The pores or voids within or surrounding the microcapillaries of the open matrix of the macroporous elements impart multiple density variations to sound waves passing through the product's structure. These density variations in the building material increase its impedance by helping to diffuse sound and reducing sound reflections, particularly at lower and higher frequencies. The products of the present invention have improved sound-deadening qualities compared to conventional building materials.

[0090] It has been found that as water and / or water vapor and / or air pass in and out of the microcapillary structure of the macroporous elements of the products of the invention, volatile organic compounds are also absorbed within the open matrix, e.g., within the voids of the open matrix and / or within the microcapillary structure of the product. The microcapillary structure of the product has been found to sequester the volatile organic compounds and absorb a greater amount of the volatile organic compounds than is released back into the environment. Thus, the present invention provides bioaggregate-based building materials with improved air quality and / or air purification capabilities in the environment compared to conventional building materials.

[0091] Lignocellulosic bioaggregates may further comprise one or more additional organic and / or inorganic components, such as, for example, pectins, waxes, fats, water-soluble components and ash, and any combination thereof.

[0092] The calcium carbonate-derived binder is preferably present in the form of a steam-open mineral blend. The calcium carbonate-derived binder may be in the form of calcium hydroxide (slaked lime), calcium oxide hydrate. Preferably, the calcium carbonate-derived binder is formed from CL-90 slaked lime. The calcium carbonate-derived binder may be formed from calcium oxide (quicklime). The calcium carbonate-derived binder may be formed from calcium hydroxide and calcium oxide. The calcium carbonate-derived binder may be formed from one or more of calcium hydroxide and / or calcium oxide in combination with one or more of lime putty and / or milk of lime. The calcium carbonate-derived binder may be in the form of natural hydraulic lime.

[0093] The calcium carbonate-derived binder may be in the form of a slurry or suspension. The rheology of the slurry or suspension may be relatively low due to the narrow particle size distribution. The rheology of the calcium carbonate-derived binder, when in the form of a suspension or slurry, may be improved by adding one or more rheology modifiers to the calcium carbonate-derived binder. The one or more rheology modifiers may be selected from one or more of sodium water glass (sodium silicate), calcareous groats (a by-product of the slaking process), and / or magnesium lime (e.g., containing at least 5% magnesium oxide by weight and / or between 5% and 35% magnesium carbonate by weight). The at least one rheology modifier may be present in the calcium carbonate-derived binder in an amount of at least 1% by weight. The at least one rheology modifier may be present in the calcium carbonate-derived binder in an amount of up to 20% by weight. The at least one rheology modifier may be present in the calcium carbonate-derived binder in an amount between 1% and 20% by weight.

[0094] The rheology of the calcium carbonate-derived binder may be improved by the addition of at least one rheological agent. The at least one rheological agent may include one or more naturally occurring sugars or carbohydrates. The naturally occurring sugars may be selected from one or more of monosaccharides, disaccharides, common sugars (such as fructose, sucrose, or glucose), or any combination thereof. The naturally occurring sugars are preferably one or more of cellulose, starch, hemicellulose, chitin, chitinous substances, glycogen, or any combination thereof.

[0095] In one embodiment, the method for producing a building material may further comprise priming a surface configured to contact the calcium carbonate-derived binder and bioaggregates with milk of lime, which is a suspension of calcium hydroxide in water. The surface may be primed before or during the production of the building material, for example, before or during deposition or extrusion. Such surfaces include, but are not limited to, the surfaces of one or more of the following: backing papers with varying densities; structural elements including hollow-core extrusions or timber elements; and co-extruded boards with organic or inorganic binder matrices. In one embodiment, the calcium carbonate-derived binder may be provided as a slurry or suspension, for example, a milk of lime suspension. In one embodiment, the calcium carbonate-derived binder slurry or suspension may include at least one rheological agent and / or one or more deflocculating agents. The combination of the calcium carbonate-derived binder with the rheological agent and deflocculating agent provides a reactive primer that can provide a very thin layer of calcium carbonate with a high surface area and good contact with the substrate during production.

[0096] The calcium carbonate-derived binder is preferably present in the building material in an amount of at least 10 wt.%, preferably at least 20 wt.%, preferably at least 30 wt.%, for example about 35 wt.%, of the total weight of the mixture. The calcium carbonate-derived binder is preferably present in the building material in an amount of not more than 90 wt.%, preferably not more than 80 wt.%, preferably not more than 70 wt.%, preferably not more than 60 wt.%, for example not more than about 55 wt.%, of the total weight of the mixture. In one embodiment, the calcium carbonate-derived binder is present in the building material in an amount between 10 wt.% and 90 wt.%, preferably between 20 wt.% and 80 wt.%, preferably between 30 wt.% and 70 wt.%, for example between 35 wt.% and 55 wt.%, of the total weight of the mixture.

[0097] The calcium carbonate-derived binder may be present in the form of lime, hydrated lime (or hydrated calcium carbonate), or modified lime. The method may further comprise treating raw calcium carbonate to produce hydrated calcium carbonate as the calcium carbonate-derived binder.

[0098] In one embodiment, the calcium carbonate-derived binder is provided in a powder form. The calcium carbonate-derived binder powder may be introduced into water to form a calcium carbonate-derived binder slurry. The calcium carbonate-derived binder slurry may be mixed with lignocellulosic bioaggregates and then set into a range of different shapes. The calcium carbonate-derived binder slurry may be used in any method suitable for manufacturing building materials, such as casting, deposition, or extrusion, to produce building materials having predetermined shapes and / or dimensions. The method of the present invention allows for a range of different shape products to be formed from a mixture of lignocellulosic bioaggregates and calcium carbonate-derived binder.

[0099] The bioaggregates are preferably present in the building material in an amount of at least 5 wt.%, preferably at least 10 wt.%, preferably at least 15 wt.% of the total weight of the mixture. The bioaggregates are preferably present in the building material in an amount of no more than 60 wt.%, preferably no more than 50 wt.%, preferably no more than 40 wt.%, more preferably no more than 30 wt.% of the total weight of the mixture. In one embodiment, the bioaggregates are present in the building material in an amount ranging from 5 wt.% to 60 wt.%, preferably from 10 wt.% to 50 wt.%, preferably from 15 wt.% to 40 wt.%, more preferably from 15 wt.% to 30 wt.% of the total weight of the mixture.

[0100] The ratio of calcium carbonate derived binder to bioaggregates by weight is preferably at least 1:1, preferably at least 1.5:1, preferably at least 1.75:1, preferably at least 2:1, more preferably at least 2.2:1. The ratio of calcium carbonate derived binder to bioaggregates by weight is preferably 6:1 or less, preferably 5.5:1 or less, preferably 5:1 or less. The ratio of calcium carbonate derived binder to bioaggregates by weight is preferably in the range between 1:1 and 6:1, preferably in the range between 1.5:1 and 5.5:1, preferably in the range between 1.75:1 and 5:1, preferably in the range between 2:1 and 5:1.

[0101] The density of the building material after drying is 350 kg / m 3 ~850kg / m 3 in the range between 400 kg / m 3 ~800kg / m 3 in the range between 350 kg / m 3 ~750kg / m 3 It may be in the range between.

[0102] The building material may further comprise at least one rheological agent. In one embodiment, the at least one rheological agent comprises at least one sag-reducing rheological agent. The at least one sag-reducing rheological agent is preferably selected from one or more of nanocellulose fibers, microfibrillated cellulose, hydroxyethyl cellulose, methyl cellulose, or any combination thereof. Preferably, the at least one The sag reducing rheological agent is methylcellulose.

[0103] The inclusion of at least one sag-reducing rheology agent facilitates achieving predetermined flow characteristics of the bioaggregate and calcium carbonate-derived binder during mixing and deposition, e.g., sequential extrusion. The presence of at least one sag-reducing rheology agent in the mixture of calcium carbonate-derived binder and bioaggregate can facilitate achieving predetermined flow characteristics such that the mixture can be imparted or formed into complex geometries, providing a castable mixture basis, specifically 3D printing of buildings in their entirety, elements, or components, without the requirement for molds. In one embodiment, the mixture can be extruded into a temporary form. The mixture can set more quickly, resulting in the temporary form being removed more quickly. In one embodiment, the mixture can be extruded between backing paper, onto other laminates, or between other laminates. The mixture can set more quickly, resulting in faster transport.

[0104] In one embodiment, the at least one rheological agent comprises at least one flow-increasing rheological agent, which may be selected from one or more of calcium lignosulfinate, sodium lignosulfonate, ammonium lignosulfonate, sulfonated naphthalene formaldehyde condensate, sulfonated melamine formaldehyde condensate, acetone formaldehyde condensate, polycarboxylate ethers, or any combination thereof.

[0105] It has been found that the mechanical properties of building materials may be improved by including at least one sag-reducing rheological agent together with at least one flow-increasing rheological agent. It has been found that by including both a sag-reducing rheological agent and at least one flow-increasing rheological agent in the mixture, the amount of water required can be reduced to a minimum, thus increasing the final compressive strength of the product.

[0106] The building material preferably comprises at least 0.1 wt. %, preferably at least 0.2 wt. %, preferably at least 0.3 wt. %, for example about 0.5 wt. %, based on the total weight of the mixture of at least one rheological agent, preferably at least one sag-reducing rheological agent.

[0107] The building material preferably comprises at most 5% by weight, preferably at most 4% by weight, for example at most 2.5% by weight, based on the total weight of the mixture of at least one rheological agent, preferably at least one sag reducing rheological agent.

[0108] The building material preferably comprises at least one rheological agent in an amount between 0.1% and 5% by weight, preferably between 0.2% and 4% by weight, preferably between 0.3% and 3% by weight, for example between 0.5% and 2.5% by weight of the total weight of the mixture.

[0109] The building material preferably comprises at least 0.5% by weight of the total weight of the mixture of at least one flow-increasing rheological agent, preferably at least 1% by weight, preferably at least 2% by weight, for example about 2.5% by weight.

[0110] The building material preferably comprises at most 20% by weight of at least one flow-increasing rheological agent, preferably at most 15% by weight, for example at most 12.5% ​​by weight of the total weight of the mixture.

[0111] The building material preferably comprises at least one flow-increasing rheological agent in an amount between 0.5% and 20% by weight, preferably between 1% and 15% by weight, preferably between 2% and 15% by weight, for example between 2.5% and 12.5% ​​by weight of the total weight of the mixture.

[0112] The ratio of flow-increasing rheological agent to sag-reducing rheological agent in the mixture forming the product of the present invention is preferably at least 1:1, preferably at least 2:1, preferably at least 3:1, for example about 5:1.

[0113] The ratio of flow-increasing rheological agent to sag-reducing rheological agent in the mixture forming the product of the present invention is preferably 10:1 or less, preferably 9:1 or less, preferably 8:1 or less, for example 7:1 or less.

[0114] The ratio of flow-increasing rheological agent to sag-reducing rheological agent in the mixture forming the product of the present invention is preferably in the range of between 1:1 and 10:1, preferably in the range of between 2:1 and 9:1, preferably in the range of between 3:1 and 8:1, for example in the range of 4:1 to 7:1.

[0115] The building material may further comprise at least one water retention agent. The at least one water retention agent is preferably selected from galactomannan polysaccharides including one or more of fenugreek gum, guar gum, tara gum, locust bean gum, cassia gum, or any combination thereof. The at least one water retention agent is preferably selected from non-galactomannan polysaccharides including one or more of brown algae containing alginic acid, sodium alginate, potassium alginate, ammonium alginate, calcium alginate, or any combination thereof. In one embodiment, the at least one water retention agent is preferably selected from one or more of agar, pectin, gelatin, or any combination thereof.

[0116] At least one water retention agent may be present to improve hardening, for example, by shortening the hardening time and / or to improve the mechanical properties of the calcium carbonate-derived binder, thereby improving the rate of improvement of the mechanical properties of the bioaggregate / calcium carbonate mixture. To set the binder, CO2 transfer from the atmosphere into the calcium hydroxide binder is required. This transfer occurs when carbonic acid is generated through the presence of water and CO2. This composite requires the correct diffusion of water vapor during drying, so that it occurs at an optimized rate in the mixture, ensuring cost-effective production of the building material. The correct blend and proportion of water retention agent in the mixture also ensures homogeneous and uniform water distribution when mechanical processing is performed, for example, during extrusion. This secondary function improves the material cohesion of the mixture, promoting improved architecture and chemical properties of the final building material.

[0117] The at least one water retention agent is preferably present in the building material in an amount of at least 0.1% by weight, preferably at least 0.2% by weight, preferably at least 0.3% by weight, for example about 0.5% by weight, of the total weight of the mixture.

[0118] The building material preferably comprises at most 5% by weight of at least one water retention agent, preferably at most 4% by weight, for example at most 2.5% by weight of the total weight of the mixture.

[0119] The building material preferably comprises at least one water retention agent in an amount between 0.1% and 5% by weight, preferably between 0.2% and 4% by weight, preferably between 0.3% and 3% by weight, for example between 0.5% and 2.5% by weight of the total weight of the mixture.

[0120] The building material may further comprise at least one fiber reinforcement to provide additional mechanical strength. The at least one fiber reinforcement may comprise any suitable fiber configured to provide additional mechanical strength to the building material. The at least one fiber reinforcement may be, for example, natural short fiber reinforcement, metal fiber, micro-metal fiber, synthetic fiber, mineral fiber, or any of these. The fiber reinforcement preferably comprises one or more of cellulose fibers (preferably recycled cellulose fibers), viscose fibers (preferably recycled viscose fibers), hemp fibers, flax fibers, polypropylene, glass fibers (preferably recycled glass fibers), or any combination thereof. The metal or micro-metal fibers may consist of steel.

[0121] The at least one fiber reinforcement is preferably present in the building material in an amount of at least 0.1% by weight, preferably at least 0.2% by weight, preferably at least 0.3% by weight, for example about 0.5% by weight, of the total weight of the mixture.

[0122] The building material preferably comprises at most 5% by weight of at least one fiber reinforcement, preferably at most 4% by weight, for example at most 2.5% by weight of the total weight of the mixture.

[0123] The building material preferably comprises at least one fiber reinforcement in an amount between 0.1% and 5% by weight, preferably between 0.2% and 4% by weight, preferably between 0.3% and 3% by weight, for example between 0.5% and 2.5% by weight of the total weight of the mixture.

[0124] The building material may further include a cementitious binder including one or more of natural cement, ordinary Portland cement, or any combination thereof. The cementitious binder may further include one or more pozzolan inclusions to increase the short-term and / or long-term mechanical properties of the building material. In one embodiment, ordinary Portland cement is used as a replacement for natural cement in the cementitious binder. In one embodiment, ordinary Portland cement is present as a replacement for natural cement, where ordinary Portland cement is present in an amount of about 50% by volume of the natural cement, and the remainder of the volume of the natural cement is replaced with calcium hydrate.

[0125] The one or more pozzolanic inclusions may be selected from one or more of the following: powdered fly ash (PFA), ground granulated blast furnace slag (GGBS), metakaolin, silica fume ash, or any combination thereof.

[0126] The cementitious binder may be present in an amount of at least 5% by weight of the total weight of the mixture, preferably at least 10% by weight, preferably at least 15% by weight, for example at least 20% by weight.

[0127] The cementitious binder may be present in an amount of up to 60% by weight of the total weight of the mixture, preferably up to 50% by weight, preferably up to 45% by weight.

[0128] The cementitious binder may be present in an amount ranging between 5% and 60% by weight of the total weight of the mixture, preferably ranging between 10% and 50% by weight, preferably between 15% and 45% by weight, preferably between 20% and 45% by weight.

[0129] In one embodiment, the cementitious binder comprises natural cement and ordinary Portland cement. Preferably, the ratio of natural cement to ordinary Portland cement in the cementitious binder is between 0.1:10 and 10:1, preferably between 0.2:1 and 5:1, preferably between 0.3:1 and 3:1, preferably between 0.5:1 and 2:1, for example about 2:1.

[0130] The ratio of bioaggregate to cementitious binder by weight is preferably at least 1:1, preferably at least 1.5:1, preferably at least 1.6:1. The ratio of bioaggregate to cementitious binder by weight is preferably 3.5:1 or less, preferably 3:1 or less, preferably 2.75:1 or less, preferably 2.5:1 or less. The ratio of bioaggregate to cementitious binder is preferably in the range between 1:1 and 3.5:1, preferably in the range between 1.5:1 and 3:1, preferably in the range between 1.6:1 and 2.75:1, preferably in the range between 1.6:1 and 2.5:1.

[0131] The mixture forming the product of the present invention may further comprise sand, preferably fine sand.

[0132] The sand may be present in an amount of at least 1% by weight of the total weight of the mixture, preferably at least 2% by weight, preferably at least 3% by weight, for example at least 5% by weight.

[0133] Sand may be present in an amount of up to 30% by weight of the total weight of the mixture, preferably up to 20% by weight, preferably up to 15% by weight.

[0134] The sand may be present in an amount ranging between 1% and 30% by weight of the total weight of the mixture, preferably ranging between 2% and 20% by weight, preferably between 5% and 15% by weight.

[0135] The sand is a fine, sharp sand. Preferably, the particles in the sand have a maximum particle size in the range between 0.5 mm and 2.5 mm.

[0136] The mixture may further comprise at least one secondary binder. The secondary binder facilitates an improved interface between the bio-aggregates and the calcium carbonate-derived binder. The secondary binder may provide an improved physical and chemical interface between the bio-aggregates and the calcium carbonate-derived binder. The presence of the secondary binder facilitates preventing or minimizing the risk of shrinkage of the bio-aggregates during the hardening stage of the mixture. The secondary binder may also help to fill gaps that may be present between the binder and the bio-aggregates. Suitable secondary binders include one or more of methylated cellulose, fenugreek gum, guar gum, tamarind gum, or any combination thereof.

[0137] The building material may be one or more of dry lining, insulation, structural insulated panels (SIPS), underfloor heating cassettes, ceiling tiles, wall tiles, cladding panels, blocks, bricks, tiles, lintels, modular building components, prefabricated building elements for modular buildings (including, but not limited to, one or more of walls, ceilings, floors, and / or integral heating sub-structures), or any combination thereof.

[0138] The building material is permeable to water and / or water vapor and / or air.

[0139] The building material may be formed by mixing the calcium carbonate-derived binder with the bioaggregate by continuous extrusion, for example, using off-site construction techniques. The particle size of the granules in the bioaggregate and the optional presence of rheological agents and secondary binders can provide the mixture with flow properties suitable for continuous extrusion.

[0140] In one embodiment, the product may be formed by one or more of 3D printing, and / or prefabrication by continuous extrusion, and / or co-manufacturing.

[0141] In one embodiment, one or more of a water retention agent, a rheology agent, a secondary binder, and a deflocculating agent may be present in the suspension or slurry along with the calcium carbonate derived binder.

[0142] According to a further aspect, the present invention provides a building structure comprising a plurality of building materials as described herein. The building materials may each be manufactured separately or may be co-manufactured (e.g., stacked, pressed, etc.). extrusion (e.g., continuous extrusion) and / or 3D printing), which may be assembled together to provide an architectural structure.

[0143] The method preferably comprises mixing the bioaggregates and calcium carbonate together as a dry mixture and then mixing the dry mixture with water to form a paste or slurry. In one embodiment, the bioaggregates and calcium carbonate are mixed together as a wet mixture to form a paste or slurry.

[0144] The water may be heated to any suitable temperature, for example up to 90°C, prior to mixing.

[0145] The method preferably further comprises continuous extrusion or deposition of the paste. In one embodiment, the method further comprises 3D printing the paste to form the building material.

[0146] The method preferably further includes curing the mixture of bioaggregates and calcium carbonate-derived binder to form the building material. The mixture may be cured by exposing the mixture to heat from a heat source. Heat may be applied to the newly formed product during and / or immediately after product formation, e.g., during and / or immediately after forming the mixture into the desired shape of the building material. In one embodiment, the mixture may be formed into the desired shape, e.g., by deposition or extrusion. The heat may be sufficient to reduce the initialization time. Heat may be applied by direct contact, conduction, or indirectly by convection or infrared heat. Once the product is formed, the product is then stacked in racks and transported to a drying chamber. The temperature of the drying chamber is preferably at least 20°C. The temperature of the drying chamber is preferably 40°C or less. The relative humidity (RH) of the drying chamber is preferably at least 10%, preferably at least 20%, e.g., at least 30%. The relative humidity (RH) of the drying chamber is preferably 90% or less, preferably 80% or less, preferably 70% or less. The relative humidity of the drying chamber is preferably in the range of between 10% and 90%, preferably in the range of between 20% and 80%, preferably in the range of between 30% and 70%. The product may be dried for any suitable period of time, for example, at least 1 day, preferably at least 3 days, for example, 3 to 5 days.

[0147] Embodiments of the present invention are described herein by way of example only. [Brief explanation of the drawings]

[0148] [Figure 1] FIG. 1 is a graph showing the particle size distribution of bioaggregate particles within the lignocellulosic bioaggregates forming the product of the present invention. [Figure 2] FIG. 2 is a graph showing the sound absorption coefficient of three bioaggregate-based building materials according to embodiments of the present invention compared to gypsum-based building materials. DETAILED DESCRIPTION OF THE INVENTION

[0149] Example 1 - Composition of dry mix for forming bioaggregate-based building materials The dry mix for forming the building material comprises: 15–30 wt% lignocellulosic bioaggregates. 35-55% by weight of calcium carbonate derived binder (lime). 20-45% by weight cementitious binder. 5-15% sand by weight. 0.5-2.5 wt% of rheological agent. 0.5 to 2.5% by weight of a water-retaining agent. 0.5-2.5 wt% fiber reinforcement.

[0150] The percentages are based on the weight percent of each component relative to the total weight of the dry mix.

[0151] Rheological agents include sag reducing rheological agents and flow increasing rheological agents.

[0152] Example 2 - Paste for forming bioaggregate-based building materials Water is added to the dry mixture of Example 1 to form a paste. Water is added to the dry mixture in an amount of 40-60% by weight based on the total weight of the wet mixture / paste.

[0153] A flow enhancer may also be added in an amount of 2.5% to 12.5% ​​by weight based on the total weight of water added to the dry mix.

[0154] Example 3 - Particle size distribution of lignocellulosic bioaggregates FIG. 1 shows the particle size distribution of building material lignocellulosic bioaggregates for forming a substrate having a thickness of 15 mm, according to one embodiment of the present invention.

[0155] It can be seen that 100% of the bioaggregate granules (by weight) have a maximum particle size within the range of 0.25 mm to 4.76 mm. Furthermore, 99% of the bioaggregate granules have a maximum particle size within the range of 0.25 mm to 2.38 mm. Furthermore, 98% of the bioaggregate granules have a maximum particle size within the range of 0.5 mm to 2.38 mm. Furthermore, 89% of the bioaggregate granules have a maximum particle size within the range of 1 mm to 3.36 mm. Furthermore, 76% of the bioaggregate granules have a maximum particle size within the range of 1.41 mm to 2.38 mm. Furthermore, 48% of the bioaggregate granules have a maximum particle size within the range of 2.00 mm to 2.38 mm. The 50th percentile of maximum particle sizes for the bioaggregate granules by weight can be found near 2.00 mm.

[0156] The maximum particle size of the bioaggregate granules is selected depending on the dimensions, such as the thickness, of the resulting building material. In this illustrated embodiment, the maximum particle size of the bioaggregate granules is no greater than 0.3 times the thickness of the resulting substrate. This is particularly important for thinner building materials. However, it is understood that thicker products may include additional structural reinforcing elements to provide structural rigidity to the product, and in such cases the maximum particle size of the bioaggregate granules is less important.

[0157] The particle size distribution is important to ensure that the mixture can be used for large-scale production, for example, by continuous extrusion. As shown in Figure 1, the particle size distribution of the bioaggregates can ensure that a mixture is produced with suitable viscosity, rheology, and cohesion for use in industrial processing.

[0158] Example 4 - Sound absorption coefficient of bioaggregate-based building materials Three embodiments of bioaggregate-based building materials (BB-F-001, BB-F-002, and BB-F-003) were prepared, and the sound absorption coefficient of each product was measured in comparison to a gypsum-based building material (gypsum).

[0159] From Figure 2, it can be seen that the absorption coefficients of the bioaggregate-based building materials of the present invention (BB-F-001, BB-F-002, and BB-F-003) are significantly higher than that of the gypsum product, especially at low and high frequencies. The increased absorption efficiency is a result of the pores in the macroporous element that trap air and the density changes within the product, which in turn reduces the acoustic impedance. Thus, the products of the present invention provide environmentally friendly, low density products with improved acoustic performance compared to gypsum-based counterparts.

[0160] <Additional Notes> The bioaggregate building materials described in the above-described embodiments can be understood, for example, as follows.

[0161] The bioaggregate-based building material according to the first aspect of the present disclosure comprises:

[0162] A bioaggregate-based building material according to a second aspect of the present disclosure is the bioaggregate-based building material according to the first aspect, wherein the lignocellulose bioaggregate is a pulverized lignocellulose bioaggregate.

[0163] A bioaggregate-based building material according to a third aspect of the present disclosure is the bioaggregate-based building material according to the first or second aspect, wherein the lignocellulose bioaggregate is a chemically untreated lignocellulose plant material.

[0164] A bioaggregate-based building material according to a fourth aspect of the present disclosure is one in which, in any of the first to third aspects, the proportion of bioaggregate granules forming the lignocellulose bioaggregate that have a maximum particle size within the lower 20% of the particle size range is 10% by weight or less.

[0165] A bioaggregate-based building material according to a fifth aspect of the present disclosure is a building material according to any one of the first to fourth aspects, wherein the bioaggregate granules forming the lignocellulose bioaggregate are The proportion of bioaggregate particulates having a maximum particle size within the upper 40% of the particle size range is 5% by weight or less.

[0166] A sixth aspect of the bioaggregate-based building material of the present disclosure is any of the first to fifth aspects, wherein the proportion of bioaggregate granules forming the lignocellulose bioaggregate in the building material that have a maximum particle size within the top 50% of the particle size range is 40% by weight or less.

[0167] A seventh aspect of the bioaggregate-based building material of the present disclosure is any of the first to sixth aspects, wherein the proportion of bioaggregate granules forming the lignocellulose bioaggregate having a maximum particle size within the lower 50% of the particle size range is at least 60% by weight.

[0168] An eighth aspect of the present disclosure is a bioaggregate-based building material according to any one of the first to seventh aspects, wherein the lignocellulosic bioaggregate is formed from one or more of common wheat, hemp, oat, rapeseed, barley straw, miscanthus, bamboo, flax, rice straw, corn straw, sugarcane bagasse, sisal straw, or any combination thereof.

[0169] A bioaggregate-based building material according to a ninth aspect of the present disclosure is any one of the first to eighth aspects, wherein the calcium carbonate-derived binder is present in the building material in an amount of at least 10 wt % based on the total weight of the mixture.

[0170] A bioaggregate-based building material according to a tenth aspect of the present disclosure is any one of the first to ninth aspects, wherein the lignocellulose bioaggregate is present in the building material in an amount of at least 10% by weight, based on the total weight of the mixture.

[0171] A bioaggregate-based building material according to an eleventh aspect of the present disclosure is the tenth aspect, wherein the lignocellulose bioaggregate is present in the building material in an amount ranging from 15 to 30% by weight, based on the total weight of the mixture.

[0172] The bioaggregate-based building material of a twelfth aspect of the present disclosure is any one of the first to eleventh aspects, further comprising at least one rheological agent.

[0173] A thirteenth aspect of the present disclosure provides the bioaggregate-based building material of the twelfth aspect, wherein the at least one rheological agent comprises one or more of at least one sag-reducing rheological agent and / or at least one flow-increasing rheological agent.

[0174] A bioaggregate-based building material according to a fourteenth aspect of the present disclosure is any one of the first to thirteenth aspects, further comprising at least one water retention agent.

[0175] A fifteenth aspect of the present disclosure provides the bioaggregate-based building material of the fourteenth aspect, wherein the at least one water retention agent is selected from galactomannan polysaccharides including one or more of fenugreek gum, guar gum, tara gum, locust bean gum, cassia gum, or any combination thereof, and / or non-galactomannan polysaccharides including one or more of brown algae including alginic acid, sodium alginate, potassium alginate, ammonium alginate, calcium alginate, or any combination thereof, and / or one or more of agar, pectin, gelatin, or any combination thereof.

[0176] A bioaggregate-based building material according to a sixteenth aspect of the present disclosure is any one of the first to fifteenth aspects, further comprising a fiber reinforcing material.

[0177] A seventeenth aspect of the present disclosure provides a bioaggregate-based building material according to the sixteenth aspect, wherein the fiber reinforcement is selected from one or more of natural short fiber reinforcement, metal fiber, and / or micro-metal fiber, or any combination thereof.

[0178] The bioaggregate building material of an eighteenth aspect of the present disclosure is any one of the first to seventeenth aspects, further comprising at least one cement-based binder.

[0179] The bioaggregate-based building material of a nineteenth aspect of the present disclosure, in any of the first to eighteenth aspects, is one or more of a dry lining, a thermal insulation material, a structural insulated panel (SIPS), an underfloor heating cassette, a ceiling tile, a wall tile, an exterior panel, a block, a brick, a tile, a lintel, a modular building component, a prefabricated building element, or any combination thereof.

[0180] A twentieth aspect of the present disclosure provides a method for forming a building material according to any one of the first to nineteenth aspects, comprising a macroporous element with a microcapillary structure and an open matrix to air, steam, and / or water, the method comprising mixing lignocellulose bioaggregates with a calcium carbonate-derived binder, wherein the proportion of bioaggregate granules forming the lignocellulose bioaggregate that have a maximum particle size within the lower 50% of the particle size range is between 40% and 80% by weight, and the proportion of bioaggregate granules forming the lignocellulose bioaggregate that have a maximum particle size within the upper 20% of the particle size range is 5% by weight or less.

[0181] The method of the twenty-first aspect of the present disclosure is the method of the twenty-first aspect, comprising mixing the lignocellulosic bioaggregate and the calcium carbonate derived binder together as a dry mix and then mixing the dry mix with water to form a paste.

[0182] The method of the twenty-second aspect of the present disclosure is the twenty-first aspect, further comprising forming the building material by continuous extrusion or deposition of the paste.

[0183] A kit according to a 23rd aspect of the present disclosure is a kit of parts for forming a building material according to any one of the first to 19th aspects, comprising a macroporous element with a microcapillary structure and an open matrix to air, steam, and / or water, the kit comprising: lignocellulose bioaggregates, wherein the proportion of bioaggregate granules forming the lignocellulose bioaggregate that have a maximum particle size within the lower 50% of the particle size range is between 40% and 80% by weight, and the proportion of bioaggregate granules forming the lignocellulose bioaggregate that have a maximum particle size within the upper 20% of the particle size range is 5% by weight or less; and a calcium carbonate-derived binder.

[0184] The kit of a 24th aspect of the present disclosure is the kit of the 23rd aspect, further comprising one or more of at least one rheological agent, at least one water retention agent, fiber reinforcement material, at least one coagulant, and at least one cementitious binder.

Claims

[Claim 1] A bioaggregate-based building material, a macroporous element formed from a mixture of a calcium carbonate-derived binder and lignocellulosic bioaggregates, the macroporous element having an open matrix to air, steam, and / or water, with microcapillary structures formed by the lignocellulosic bioaggregates; the porosity of the macroporous element is at least 50% of the bulk volume of the building material; the proportion of bioaggregate particulates forming the lignocellulosic bioaggregate having a maximum particle size within the lower 50% of the particle size range is between 40% and 80% by weight; The proportion of bioaggregate granules forming the lignocellulose bioaggregate having a maximum particle size within the upper 20% of the particle size range is 5% by weight or less; The particle size range is a building material that is a range from the minimum value to the maximum value of the maximum particle size of the bioaggregate granules that form the lignocellulose bioaggregate.

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