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US 2026/0296962 A1Published application
Method for manufacturing tiles with decorative surface patterns
OwnerEmily MAJEWSKIinventor
Life of this patent
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Abstract
Cementitious wet mixtures and solids such as architectural tiles providing carbon sequestration and being overall carbon negative. The cementitious solids include a binder, a catalyst, and biomass. The biomass has particular particle sizes to enable controlled non-uniform distribution of high and low concentrations of biomass to create particular dual color and/or dual color shade designs.
Claims25
1-46. (canceled)
47:
- A method comprising:
- obtaining biomass particles having a particle size not less than 50 mesh and not greater than 25 mesh;
- forming a slurry comprising:
- a binder, a catalyst, the biomass particles, and water;
- cast or press the slurry into a mold or a form liner;
- vibrate the slurry within the mold or the form liner to allow binder particles to sink to a bottom of the mold or the form liner;
- cure the slurry to form a cementitious solid;
- and
- once cured, either:
- polishing a major surface of the cementitious solid to remove from the raised portions of the major surface the top layer having a higher concentration of the mineral particles so as to reveal differently colored or shaded content inside the raised portions having a higher concentration of biomass particles compared to the non-raised portions of the major surface, or
- routering a major surface of the cementitious solid to remove portions of the major surface to form depressions or non-raised portions in the major surface, wherein the non-removed, raised portions have a higher concentration of the mineral particles so as to reveal differently colored or shaded content inside the non-raised portions having a higher concentration of biomass particles compared to the raised portions of the major surface.
8 more elements
48:
- The method according to claim 47, wherein the particle size of the biomass particles is not less than 45 mesh and not greater than 30 mesh.
49:
- A method comprising:
- obtaining biomass particles, wherein at least 90% of the biomass particles in the cementitious solid have a particle size from 250 microns to 750 microns;
- forming a slurry comprising:
- a binder, a catalyst, the biomass particles, and water;
- cast or press the slurry into a mold or a form liner;
- vibrate the slurry within the mold or the form liner to allow binder particles to sink to a bottom of the mold or the form liner;
- cure the slurry to form a cementitious solid;
- and
- once cured, either:
- polishing a major surface of the cementitious solid to remove from the raised portions of the major surface the top layer having a higher concentration of the mineral particles so as to reveal differently colored or shaded content inside the raised portions having a higher concentration of biomass particles compared to the non-raised portions of the major surface, or
- routering a major surface of the cementitious solid to remove portions of the major surface to form depressions or non-raised portions in the major surface, wherein the non-removed, raised portions have a higher concentration of the mineral particles so as to reveal differently colored or shaded content inside the non-raised portions having a higher concentration of biomass particles compared to the raised portions of the major surface.
8 more elements
50:
- The method according to claim 49, wherein at least 90% of the biomass particles in the cementitious solid have a particle size from 300 microns to 700 microns.
51:
- (canceled)
52:
- A method comprising:
- obtaining biomass particles;
- forming a slurry comprising:
- a binder, a catalyst, the biomass particles, and water;
- cast or press the slurry into a mold or a form liner, wherein the mold or the form liner includes a portion of a major surface of the mold or the form liner that is raised with respect to another portion of the major surface;
- vibrate the slurry within the mold or the form liner to allow binder particles to accumulate in a larger concentration adjacent the major surface of the mold or the form liner;
- cure the slurry to form a cementitious solid;
- and
- once cured, polish or routering a major surface of the cementitious solid to reveal a first zone of the major surface of the cementitious solid having a different color and/or darker color shade than a second zone of the major surface of the cementitious solid.
6 more elements
53:
- The method according to claim 52, wherein color shade difference (ΔL*) between the first zone and the second zone is at least 10 on L* axis of CIELAB color space.
54-56:
- (canceled)
57:
- The method according to claim 52, wherein color difference (ΔE*) between the first zone and the second zone is at least 3 on CIELAB color space.
58-60:
- (canceled)
61:
- The method according to claim 52, wherein a major surface of the cementitious solid includes a raised portion extending away from the major surface of the cementitious solid, wherein the first zone or the second zone is located in the raised portion.
62:
- The method according to claim 52, wherein the major surface of the cementitious solid includes a plurality of raised portions extending away from the major surface of the cementitious solid, wherein each of the raised portions includes substantially the same concentrations of biomass particles and thereby substantially the same color shade.
63:
- The method according to claim 62, wherein the plurality of raised portions are arranged on the major surface of the cementitious solid to form a design.
64:
- The method according to claim 52, wherein the binder comprises magnesium.
65:
- The method according to claim 64, wherein the binder comprises magnesium oxide, magnesium hydroxide, magnesium oxychloride cement, magnesium oxysulfate cement, magnesium carbonate cement, or magnesium phosphate cement.
66:
- The method according to claim 52, wherein the catalyst comprises a metal salt or ammonium salt.
67:
- The method according to claim 66, wherein the catalyst comprises an alkali metal salt.
68:
- The method according to claim 67, wherein the catalyst comprises at least one of alkali metal carbonate, alkali metal bicarbonate, or alkali metal borate.
69:
- (canceled)
70:
- The method according to claim 52, wherein the additional biomass comprises biochar, cellulose fibers, straw, hemp, rice hulls, coconut coir, corn cobs, nut husks and shells, wood mulch, and/or bark mulch.
71:
- The method according to claim 52, further comprising metal silicate.
72:
- The method according to claim 71, wherein the metal silicate comprises aluminum silicate or calcium silicate.
73:
- The method according to claim 52, wherein composition of the cementitious solid comprises 40 wt % to 75 wt % binder, 20 wt % to 57 wt % biomass, and 3 wt % to 10 wt % catalyst based on the total weight percentage of the binder, the catalyst, and the biomass.
74:
- The method according to claim 52, wherein composition of the cementitious solid comprises 30 wt % to 60 wt % binder, 5 wt % to 15 wt % non-pyrolyzed biomass, and 3 wt % to 7 wt % catalyst, and 30 wt % to 60 wt % biochar based on the total weight percentage of the binder, the catalyst, the non-pyrolyzed biomass, and the biochar.