Composite Pavers via CO2 Sequestration and Hydrothermal Sintering
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Solution Overview
Problem
Existing methods for producing artificial stone mimics face challenges such as poor reproducibility, low yield, high finishing costs, unsatisfactory mechanical properties, and high energy consumption, along with unfavorable carbon footprints, while struggling to replicate the aesthetic and physical characteristics of natural stone.
Innovation Solution
The development of novel composite paving stones and construction block materials using low-cost raw materials like particulate calcium silicate, quartz, and carbon dioxide, which are processed through gas-assisted hydrothermal liquid phase sintering to create materials with enhanced compressive strength, water resistance, and a reduced carbon footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If artificial stone mimics are prepared by blending natural stone powder and mineral particulate with Portland Cement or synthetic resin, then the material can be formed into desired shapes, but the mechanical properties remain unsatisfactory and the material deteriorates over time
Solution Approach 1:
The invention changes the chemical composition parameters by replacing traditional Portland cement or synthetic resin binders with a novel binder system comprising reactive magnesia and reactive silica. This chemical parameter change results in superior mechanical properties and long-term durability without the deterioration issues associated with conventional binders.
Solution Approach 2:
The invention creates a composite material system combining reactive magnesia, reactive silica, and mineral particulates in specific proportions. This composite approach leverages the complementary properties of each component to achieve both high mechanical strength and excellent long-term reliability, overcoming the limitations of single-material systems.
2Productivity
If traditional artificial stone production methods are used, then production can proceed with established processes, but the yield is low and finishing costs are high
Solution Approach 1:
The invention incorporates colorants, pigments, and surface treatment agents directly into the binder composition before mixing with mineral particulates. This preliminary incorporation eliminates the need for separate finishing steps, reducing both production time and finishing costs while maintaining consistent color and surface quality throughout the product.
Solution Approach 2:
The invention merges multiple functions into the binder composition itself, which simultaneously provides binding, coloring, surface treatment, and reinforcement properties. This consolidation of functions into a single material system streamlines the manufacturing process, increases yield, and reduces the need for separate processing steps.
3Use of energy by moving object
If existing artificial stone production methods are employed, then production can continue with current technology, but energy consumption is large and carbon footprint is unfavorable
Solution Approach 1:
The invention converts the harmful carbon dioxide emissions into a beneficial component by using CO2-reactive magnesia and silica that sequester carbon dioxide during the curing process. This transforms the harmful greenhouse gas into a useful binding agent, reducing the carbon footprint while maintaining production efficiency.
Solution Approach 2:
The invention changes the curing process parameters by utilizing ambient temperature and atmospheric carbon dioxide instead of high-temperature kiln curing. This parameter change dramatically reduces energy consumption and eliminates the need for fuel-intensive heating processes, thereby reducing both energy use and carbon emissions.
4Strength
If natural stone is used for construction and decoration, then aesthetic and physical qualities are achieved, but the material is expensive and scarce
Solution Approach 1:
The invention creates artificial stone mimics that replicate the aesthetic appearance and physical properties of natural stone through careful selection of mineral particulates and colorants. The resulting material closely copies the visual characteristics of natural stone while being produced from abundant, low-cost raw materials, making it an economical alternative.
Solution Approach 2:
The invention uses locally available mineral particulates such as sand, gravel, and industrial by-products as aggregate materials. By sourcing materials locally rather than importing expensive natural stone, the invention reduces costs while maintaining the desired aesthetic and physical qualities through proper material selection and mixing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in composite materials that simulate the appearance and feel of natural stone, offering improved mechanical properties, reduced environmental impact, and efficient production, with compressive strengths ranging from 50 MPa to 300 MPa and water absorption less than 10%, while sequestering CO2 and reducing primary efflorescence.
Implementation Method 1
The composite construction material comprises a plurality of bonding elements, wherein each bonding element comprises: a core comprising primarily calcium silicate, a silica-rich first or inner layer, and a calcium carbonate-rich second or outer layer
Implementation Method 2
processed through gas-assisted hydrothermal liquid phase sintering to create materials with enhanced compressive strength
Implementation Method 3
the bonding elements and the filler particles are configured to be bonded together as a result of a reaction in which an atmosphere comprising more than 50% carbon dioxide is present
Data Source
AI summary
The invention provides novel paving stones and construction block composite materials and methods for preparation thereof. The paving stones and construction block composite materials can be readily produced from widely available, low cost precursor materials by a production process that involves compacting in a mold that is suitable for large-scale production. The precursor materials include calcium silicate, for example, wollastonite, and particulate filler materials which can comprise silicon dioxide-rich materials. Additives can include calcium carbonate-rich and magnesium carbonate-rich materials. Various additives can be used to fine-tune the physical appearance and mechanical properties of the composite material, such as colorants such as particles of colored materials, such as, and pigments (e.g., black iron oxide, cobalt oxide and chromium oxide). These paving stones and construction block composite materials exhibit visual patterns similar to stone as well as display compressive strength and water absorption equal to or better than that of stone.