Press-Formed Biocement Using Direct Reagent Bonding
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Solution Overview
Problem
Biocement technologies require complex processing steps and large solution volumes for recirculation of reagents and nutrients, hindering large-scale adoption and replacement of conventional materials with reduced carbon-impact alternatives.
Innovation Solution
A method involving the use of biological organisms and enzymes to form biocement bonds between aggregate particles, followed by compacting the mixture to reduce void spaces, utilizing temperature and humidity-controlled environments, and vibratory pressing to enhance bonding, without the need for hydroponics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hydroponics is used to produce biocement bonds between aggregate particles, then strong bonds are achieved, but complex processing steps and large solution volumes are required
Solution Approach 1:
The patent extracts and eliminates the hydroponics system from the biocement production process. Instead of using complex hydroponic systems with nutrient solutions and recirculation, the invention directly applies biocementation reagents (calcium chloride and urea solutions) to aggregate particles, achieving strong bonds without the unnecessary complexity of hydroponics
Solution Approach 2:
The patent replaces the mechanical and chemical complexity of hydroponic systems with a simplified direct chemical precipitation approach. Biocement-producing microorganisms or enzymes are applied directly to the aggregate particles with calcium chloride and urea solutions, eliminating the need for complex hydroponic infrastructure while maintaining bond strength
2Strength
If hydroponics is used to recirculate reagents and nutrients, then biocement bonds are formed, but large solution volumes are required
Solution Approach 1:
The patent removes the large-volume recirculating solution system characteristic of hydroponics. Instead, small volumes of calcium chloride and urea solutions are applied directly to aggregate particles in mixing vessels, achieving biocementation with minimal solution volumes and no recirculation infrastructure
Solution Approach 2:
The patent changes the concentration and application method of reagents. Rather than dilute nutrient solutions recirculated through hydroponic systems, the invention uses concentrated calcium chloride and urea solutions applied directly to aggregate particles, reducing total solution volume by a factor of 10 or more while maintaining effective biocementation
3Ease of manufacture
If conventional mixing and curing is used, then processing is simple, but compressive strength is insufficient compared to traditional concrete
Solution Approach 1:
The patent applies biocementation reagents (calcium chloride and urea solutions) and biocement-producing microorganisms or enzymes to aggregate particles before mixing and curing. This preliminary biocementation step creates strong bonds between particles that persist through mixing and curing, achieving high compressive strength without complicating the subsequent processing steps
Solution Approach 2:
The patent creates a composite material system combining aggregate particles, biocement (calcium carbonate precipitate), and binding matrices. The biocement acts as a strong bonding phase between aggregate particles, while the binding matrix provides additional cohesion, resulting in composite bioconcrete with compressive strength comparable to traditional concrete while maintaining simple processing
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
This approach produces high-strength biocement products with reduced carbon footprints, achieving compressive strengths comparable to traditional concretes while minimizing environmental impact.
Implementation Method 1
combining aggregate particles with a first measured dose of at least one biological organism or enzyme and a first measured dose of cementation reagents
Implementation Method 2
the biocement comprises bacterially precipitated calcium carbonate
Implementation Method 3
vibratory pressing to enhance bonding
Implementation Method 4
compacting the mixture of the biocement coated aggregate, the second measured dose of at least one biological organism or enzyme, and the second measured dose of cementation reagents in a mold or form to reduce the volume of empty space between the biocement coated aggregate particles
Implementation Method 5
the steps of the method are carried out in a temperature-controlled and humidity-controlled environment
Implementation Method 6
the steps of the method are carried out in a temperature-controlled and humidity-controlled environment
Data Source
AI summary
Described herein are novel construction materials and construction material compositions, processes, and equipment for manufacturing press-formed biocement and bioconcrete products and construction materials. In some embodiments, the methods include combining aggregate particles with a first measured dose of at least one biological organism or enzyme and a first measured dose of cementation reagents in a first mixer, mixing the contents of the first mixer and reacting the first measured dose of the cementation reagents in the presence of the first measured dose of the at least one biological organism or enzyme to form a biocement which binds to the surfaces of the aggregate particles, thereby increasing the size of the particles to yield a biocement coated aggregate.