A production process and production equipment for a pultruded foam glass composite board

Abstract

The invention relates to the technical field of composite materials, specifically to a production process and production equipment for a pultruded foam glass composite board, which includes six units: feeding and pressurizing, heating and foaming, forming and cooling, finished product treatment, traction and pulling out, and automatic control. The process is as follows: each component of the powder raw material sequentially completes grinding, metering, mixing, lifting, pushing, and pressurizing, and then enters the heating and foaming unit together with the tensile wire for heating. After becoming a high-temperature foaming fluid, it flows into the forming and cooling unit, and successively undergoes forming, annealing, primary cooling, and cooling to generate a slab with tensile wires evenly distributed on the upper and lower sides. Moreover, under the traction of the traction and pulling out unit, the slab automatically enters the finished product treatment unit, and successively undergoes plate cutting, plate edge treatment, surface treatment, and finished product curing to become a foam glass composite board. The beneficial effects are as follows: the length of the board can be cut according to requirements, the board thickness can be automatically adjusted, tensile materials are embedded on both sides of the slab, and the production process is automated, energy-saving, and environmentally friendly.

Description

Technical Field

[0001] The present invention relates to the technical field of composite materials, and particularly relates to a production process and production equipment for a pultruded foam glass composite board. Background Art

[0002] Foam glass was first invented by Pittsburgh Corning Corporation in the United States. It is an inorganic non-metallic glass material made from crushed glass, foaming agents, modified additives, foaming accelerators, etc. After being finely pulverized and uniformly mixed, it is then subjected to high-temperature melting, foaming, and annealing. The production processes of foam glass mainly include the Pittsburgh-Corning method, the recycling-molded method, the recycling-unmolded method, the granule method, and the float-ribbon method. Currently, the most widely used process at home and abroad is the "two-step powder firing method" which has become a publicly available technology.

[0003] The so-called "two-step powder firing method" is to first grind the raw materials (such as waste glass, etc.) together with auxiliary materials and foaming agents, and mix them into a uniform batch powder. Then, the batch powder is loaded into a heat-resistant steel mold box and put into a foaming kiln for heating together, so that the batch melts, foams and expands to fill the mold box. Then, it is quickly cooled to solidify the outer shell of the molten foam body. After that, it is taken out of the mold box (demolded), and then concentrated in another annealing furnace for slow cooling (annealing) to eliminate stress, forming a foam glass blank (blank material). Finally, mechanical cutting and other methods are used to process the blank material into finished products of various specifications and shapes. It can be seen that this method not only requires demolding, has low production efficiency, but also results in high energy consumption due to the rapid cooling of the molten foam body. In particular, the product size is limited by the mold, and it is even more impossible to produce composite foam glass plates embedded with tensile materials.

[0004] CN201711005959.4 discloses "a device and preparation method for producing foam glass by an unmolded method. The device includes a grinding machine, a stirrer, a foaming kiln, a turning mechanism, and an annealing furnace connected in sequence. A cutting machine is arranged between the foaming kiln and the turning mechanism. The foaming kiln and the turning mechanism are connected by a first conveyor mechanism, and the turning mechanism and the annealing furnace are connected by a second conveyor mechanism. The turning mechanism includes a turning inclined block, a turning baffle, and a turning cylinder. The turning inclined block is arranged below the first conveyor mechanism, the turning baffle is arranged on one side of the turning inclined block, the second conveyor mechanism is arranged below the turning inclined block and the turning baffle, and the turning baffle is connected to the turning cylinder; by setting a turning mechanism between the foaming kiln and the annealing furnace, the foam glass block enters the annealing furnace in a vertical state to complete the annealing work, avoiding the problem of poor annealing uniformity of the foam glass block. At the same time, the long annealing time also leads to an increase in the length and volume of the annealing furnace, increasing the production and manufacturing cost". It can be seen that this invention mainly solves the problems of demolding and vertically placing the slab into the annealing furnace, and still has many problems existing in the above "two-step powder firing method".

[0005] In the authorized invention patent "A Composite Foam Glass Self-Insulating and Facade-Free Exterior Wall Panel" (Patent No. ZL201310325951.1, Certificate No. 2299748), the applicant of this patent disclosed that "the composite foam glass self-insulating and facade-free exterior wall panel includes a slab, a fiberglass protection layer, a carbon fiber reinforcement layer, an interior wall finish layer, an exterior wall finish layer, and a panel edge member installed on the slab. The slab includes foam glass and wire meshes attached to both sides of the foam glass. The fiberglass protection layer is installed outside the slab. The carbon fiber reinforcement layer wraps the slab and the fiberglass protection layer. The interior wall finish layer and the exterior wall finish layer are installed on the inner and outer sides of the composite foam glass self-insulating and facade-free exterior wall panel".

[0006] Taking the above composite wall panel as the supporting material, the applicant of this patent presided over the general project of the National Natural Science Foundation of China "Research on the Prefabrication Transformation Mode of Existing Building Exterior Walls in the Yangtze River Delta Region" (51878588), the research and development project of the Ministry of Housing and Urban-Rural Development "Research on the Prefabrication Transformation Mode of Existing Building Exterior Walls" (2018-K9-060), and the Yangzhou Natural Science Foundation project "Research on the Mechanism and Method of Exterior Wall Prefabrication in the Transformation of Existing Buildings in the Yangtze River Delta Region". However, in the subsequent industrialization, there are still relatively large problems in aspects such as the automation and low energy consumption of production, the flexibility and accuracy of dimensions, the diversity and efficacy of finishes, and the strength and thermal insulation performance of materials. In particular, the technical solution with wire mesh as the tensile material in the original invention is difficult to implement, and it is urgent to develop a scientific and reasonable production process and core equipment for foam glass composite wall panels. Summary of the Invention

[0007] The present invention aims to solve the technical problems existing in the prior art. For this purpose, the present invention provides a pultrusion method for producing foam glass composite panels and its production equipment to solve the problems raised in the above background technology.

[0008] Based on the above purposes, the invention provides the following technical solutions:

[0009] First, due to different building storeys and different-sized doors and windows on the wall, the sizes of composite wall panels in different projects and different positions vary greatly. Obviously, the production by the mold method cannot meet the requirements. Therefore, the present invention has developed a method for producing continuous and full-length foam glass plates, and the produced slab can be automatically and accurately cut according to the actual length requirements;

[0010] Second, foam glass is a brittle material with poor tensile, shear, and bending resistance, and cannot meet the strength requirements of composite wall panels. For this reason, by setting tensile materials on both sides of the slab, a stress structure similar to that of reinforced concrete slabs is formed, which not only improves the stress performance of the composite panels but also provides a prerequisite for the slab to be pulled out of the equipment in terms of material tensile strength;

[0011] Thirdly, there are also many problems with the technical solution of the "steel wire mesh" in the existing invention in aspects such as transmission, traction, expansion and contraction, and splicing. Through multiple tests, the present invention uses tensile wires, such as stainless steel wires, high carbon steel wires, carbon fibers, etc., to replace the original "steel wire mesh", which not only facilitates the movement, traction, and distribution of the tensile wires in the equipment, but also is convenient for extension and splicing, and avoids joints at the same position, resulting in unreliable strength;

[0012] Fourthly, to produce continuous and full-length foam glass plates, it is necessary to solve the problem of automatically pulling the slab out of the equipment. Through multiple tests, a "pulling-extruding" technical method is constructed - using the traction pulling-out unit, tensile wires, and wire distribution device to achieve "pulling", and using the feeding and pressurizing unit and the heating and foaming unit to achieve "extruding";

[0013] Fifthly, in order to achieve the above "pulling-extruding", the heating and foaming part is vertically arranged, and the forming and cooling part is horizontally arranged, forming an L-shaped structure both inside and outside. This not only generates a downward extrusion force due to the self-weight of the powder raw materials and high-temperature foaming fluid, but also is conducive to the high-temperature foaming fluid flowing into the forming and cooling cavity for forming and cooling, and is also conducive to the pulling out of the slab and the utilization of waste heat;

[0014] Sixthly, the waste heat of the forming and cooling part is used for primary heating and preheating, and a highly efficient and reliable heat insulation layer and an automatic control system are set up to reduce energy consumption;

[0015] Seventhly, the processes such as slab reinforcement, performance improvement, and surface treatment are automatically completed to improve the automation of production and the adaptability of products.

[0016] Specifically, the technical solution of the present invention is as follows:

[0017] A production process and production equipment for a pulling-extruding foam glass composite plate, comprising a feeding and pressurizing unit, a heating and foaming unit, a forming and cooling unit, a finished product processing unit, a traction pulling-out unit, an automatic control unit, and a steel frame for installing these units.

[0018] Its main process is as follows: each component of the powder raw materials is successively ground, metered, and mixed in the feeding and pressurizing unit. After becoming the mixed powder, it is then lifted, pushed, and pressurized, and enters the heating and foaming unit together with the tensile wire. Then, it successively undergoes primary heating, secondary heating, tertiary heating, quaternary heating, and quinary heating. After becoming the high-temperature foaming fluid, it flows into the forming and cooling unit, and successively undergoes forming, annealing, primary cooling, and cooling to become a slab with tensile wires evenly distributed on the upper and lower sides and a width of B. Moreover, under the traction of the traction and pulling-out unit, it enters the finished product processing unit, and successively undergoes plate truncation, plate edge treatment, surface treatment, and finished product curing, and finally becomes a foam glass composite board. And all the above process steps are automatically completed under the control of the automatic control unit.

[0019] The heating and foaming unit is vertically arranged, and the forming and cooling unit is horizontally arranged. The two form an L-shaped structure, and its internal is an L-shaped cavity that is interconnected and heat-resistant. Not only will the powder raw materials and the high-temperature foaming fluid generate a downward extrusion force under the action of their own weights, but it is also beneficial for the high-temperature foaming fluid to flow into the forming and cooling cavity for forming and cooling, and it is also beneficial for the pulling out of the slab and the utilization of waste heat.

[0020] For the L-shaped structure, the higher side, that is, the side far from the forming and cooling unit, is defined as the left side, and the side opposite to the left side is defined as the right side.

[0021] The pulling and extrusion method is a technical method that realizes "pulling" by using the traction and pulling-out unit, the tensile wire, and the wire distribution device, and realizes "extrusion" by using the feeding and pressurizing unit and the heating and foaming unit.

[0022] The feeding and pressurizing unit includes the respective raw material tanks, grinders, meters of the powder raw materials, as well as the conveying pipe, mixer, elevator, powder inlet, feeding cavity, pushing rod, extrusion rod that the mixed powder successively passes through, and also the first exhaust pipe, cavity wall, and wire distribution device. Among them, the bottom of the raw material tank is connected to the feed inlet of the grinder, the discharge outlet of the grinder is connected to the feed inlet of the meter, the discharge outlet of the meter is connected to the feed inlet of the conveying pipe, the discharge outlet of the conveying pipe is connected to the feed inlet of the mixer, the discharge outlet of the mixer is connected to the feed inlet of the elevator, the discharge outlet of the elevator is connected to the powder inlet, the pushing rod is horizontally arranged at the bottom of the feeding cavity, disperses and pushes the mixed powder towards the feed inlet of the extrusion rod. The pushing rod is a spiral auger driven by a motor. The feeding cavity is located above the heating and foaming unit and is a cavity surrounded by the cavity wall. The conveying pipe, elevator, and extrusion rod are all tubular spiral conveyor structures driven by motors. Among them, the extrusion rod is vertically arranged, the upper end of its sleeve is flush with and fixed to the bottom plate of the feeding cavity, the lower part is inserted into the heating and foaming unit, and its main shaft extends outside the cavity wall and is driven by gear transmission and a motor.

[0023] The technical principles of the feeding and pressurizing unit are as follows: First, due to the small particle size of the powder raw materials, agglomeration is likely to occur, so grinding is required before weighing. Second, each component of the raw materials needs to be weighed separately to ensure the accuracy of the raw material ratio. Third, after the weighed powder raw materials enter the conveying pipe, they will start to mix under the action of the spiral blades and complete full mixing in the blender. Fourth, the setting of the pushing rod ensures the uniform distribution of the powder raw materials in the feeding cavity and the mouth of the extrusion rod. Fifth, the extrusion rod uses the spiral blades to squeeze the mixed powder raw materials downward. Sixth, preheating the powder raw materials through heat exchange can not only reduce energy consumption but also facilitate the drying of the powder raw materials.

[0024] The interior of the heating and foaming unit is a furnace chamber with a rectangular plane whose length is equal to B, enclosed by a left trough-shaped furnace wall and a right detachable flat furnace wall. From the inside to the outside, there are a furnace liner, a heat insulation layer, and a shell in sequence. An extrusion rod, multiple heating tubes, and a temperature measuring instrument are installed from top to bottom in sequence.

[0025] The heating temperatures in the furnace chamber from top to bottom are primary heating, secondary heating, tertiary heating, quaternary heating, and quinary heating, and their corresponding heating temperatures are 60°C - 120°C, 240°C - 300°C, 420°C - 480°C, 600°C - 680°C, and 750°C - 900°C respectively. Except for the primary heating, the rest are heated by the heating tubes. The heating tubes are multiple high-temperature-resistant electric heating tubes, located on the long axis of the rectangular plane, arranged in a form of one row and multiple columns, and a temperature measuring instrument is also provided beside each heating tube. The primary heating is located in the furnace chamber at the extrusion rod, and is heated by using the waste heat utilization device arranged below the feeding cavity on the outside of this section of the furnace chamber.

[0026] The technical principles of the heating and foaming unit are as follows: First, the high-temperature section is at the bottom and the low-temperature section is at the top, which is not only conducive to isolating oxygen during high-temperature heating, reducing heat loss and combustion reactions, but also conducive to maintaining pressure and the pores of the foam, as well as the flow of the foam into the molding cavity. Second, the electric heating tubes arranged in one row and multiple columns are conducive to accurately and segmentally controlling the temperature in the furnace chamber. Third, the furnace chamber is connected to the feeding cavity through the extrusion rod, and the feeding cavity is also provided with an exhaust pipe, ensuring the pressure safety of the furnace chamber. Fourth, the furnace chamber is provided with an efficient heat insulation layer to reduce energy loss.

[0027] The interior of the forming and cooling unit is a horizontal cavity with a rectangular cross-section whose length is equal to B, enclosed by a U-shaped cavity wall at the bottom and a detachable top cover at the top. From the inside to the outside, there are an inner wall, a heat-insulating layer, and a shell in sequence. The horizontal cavity communicates with the bottom of the furnace and is separated by a slab thickness control device. The horizontal cavity is divided into a forming cavity, an annealing cavity, a primary cooling cavity, and a cooling cavity in sequence from left to right. Its right end is the slab outlet. Among them, partition plates are provided between the annealing cavity and the forming cavity and the primary cooling cavity for separation. The partition plates are heat-resistant and highly elastic. The upper part is fixed to the top surface of the cavity wall, and the lower part inclines to the right, which does not affect the movement of the slab and can prevent gas from flowing into the chambers on the high-temperature side. The slab thickness control device is installed on the straight furnace wall and is driven by a motor to move up and down, and the thickness of the slab is controlled by controlling the flow rate of the high-temperature foaming fluid.

[0028] A heat-insulating layer is also provided outside the horizontal cavity. A plurality of temperature-measuring rods and heat-resistant cameras extending into the cavity are arranged at intervals on the upper side wall inside. Annealing cavity exhaust holes, annealing cavity communication holes, primary cooling cavity exhaust holes, and primary cooling cavity communication holes are respectively provided on the top surface and the upper part of the side wall on the high-temperature side of the annealing cavity and the primary cooling cavity. Among them, the annealing cavity exhaust holes discharge the high-temperature gas in the annealing cavity to the waste heat utilization device through the annealing cavity exhaust duct arranged in the heat-insulating layer, and the primary cooling cavity exhaust holes discharge the gas in the primary cooling cavity to the waste heat utilization device through the primary cooling cavity exhaust duct arranged in the heat-insulating layer. The annealing cavity exhaust duct and the primary cooling cavity exhaust duct are arranged in the heat-insulating layers of the top cover and the straight furnace wall.

[0029] Forming cavity air-cooling pipes, annealing cavity air-cooling pipes, primary cooling cavity air-cooling pipes, and water-cooling pipes are respectively provided in the bottom heat-insulating layers of the forming cavity, the annealing cavity, the primary cooling cavity, and the cooling cavity. The inlet ends of these air-cooling pipes and water-cooling pipes are respectively located on the low-temperature side of their corresponding chambers, and valves and pressurizing devices are respectively provided. The outlet ends of the forming cavity air-cooling pipe and the annealing cavity air-cooling pipe communicate with the annealing cavity communication hole, and the outlet end of the primary cooling cavity air-cooling pipe communicates with the primary cooling cavity communication hole.

[0030] The technical principles of the heating and foaming unit are as follows: First, the slab thickness control device is driven by a motor and can move up and down. By controlling the flow rate and flow velocity of the high-temperature foaming fluid entering the forming cavity, the thickness of the slab is further controlled; Second, under the cooling of the forming cavity air-cooling pipe, the lower surface and both sides of the molten foam will cool and solidify, and the upper surface will also quickly solidify due to the heat dissipation through the top surface and the annealing cavity exhaust holes; Third, since the tensile wires are distributed on the upper and lower surfaces of the molten foam, the tensile wires will be embedded in the upper and lower surfaces of the slab during the solidification process of the slab; Fourth, for the formed slab, since the internal temperature is higher than the surface temperature, it is slowly cooled in the annealing cavity to eliminate the temperature stress; Fifth, the temperature in the primary cooling cavity is still relatively high, so air-cooling is adopted for cooling; Sixth, the temperature in the cooling cavity is relatively low, so water-cooling and air-cooling are adopted for rapid cooling; Seventh, the waste heat of air-cooling and water-cooling is respectively used for primary heating and preheating to reduce energy consumption.

[0031] The traction and pulling-out unit includes a traction roller group, a heat-resistant conveyor belt, as well as an upper driving roller, a high-temperature roller, a lower driving roller, a lower driven roller, a tension adjustment roller, and an upper driven roller that the conveyor belt passes through in sequence. Among them, the upper driving roller is located on the left side of the feeding cavity and above the trough-shaped furnace wall; the high-temperature roller is located at the inner corner of the L-shaped cavity; the lower driving roller is located at the lower part outside the slab outlet; the lower driven roller is located outside the outer corner of the L-shaped structure; the upper driven roller is located directly above the lower driven roller; the tension adjustment roller is located between the upper driven roller and the lower driven roller. The upper driving roller and the lower driving roller are driven by motors. The high-temperature roller is installed on the side wall of the furnace chamber through heat-resistant sealing rings and bearings, and is provided with a heat-resistant shield.

[0032] The traction roller group is located on the right side of the slab outlet and consists of multiple rollers driven by motors. It is divided into upper and lower groups and presses tightly against the upper and lower surfaces of the slab through a pressing mechanism, moving in the direction of pulling out the slab outward.

[0033] The wire distribution device is located on the left outer side of the heating and foaming unit and is fixed on the steel frame. It includes a coil bracket, an arrangement guiding roller, a tension straightening roller, a wire break detection device, and a turning roller that the tensile wire passes through in sequence. The tensile wire is multiple continuous wires with the raw material being coils. After passing through the turning roller, it moves upward along the surface of the conveyor belt, turns over the upper driving roller and then moves downward, enters the furnace chamber. Then, half of the tensile wire passes under the high-temperature roller, enters the horizontal cavity, and is embedded in the lower part of the slab. The other half of the tensile wire passes under the sleeve and the slab thickness control device and is embedded in the upper part of the slab. At the initial stage of production before the slab is formed, the tensile wire also needs to pass through the traction roller group, be fixed on the pulling-out roller, and use it to tension and pull out the tensile wire.

[0034] The sleeve is sleeved on the outside of the heating pipe at the slab thickness control device, and the pulling-out roller is installed in the finished product processing unit. The tensile wire moves with the slab, and the slab is formed on the conveyor belt and is sequentially pulled by the conveyor belt, the traction roller group, and the pulling-out roller.

[0035] The technical principles of traction and pulling-out are as follows: First, since the slab is formed on the conveyor belt, it will be pulled out of the horizontal cavity by the conveyor belt; Second, after the slab is pulled out of the horizontal cavity, it will continue to move towards the finished product processing unit under the traction of the traction roller group; Third, the cut slab will continue to move in the finished product processing unit under the traction of the pulling-out roller to complete the finished product processing; Fourth, the upper and lower surfaces of the slab are embedded with tensile wires, which provides the required compressive strength for the roller traction. Otherwise, the slab will be pulled apart; Fifth, since the tensile wires are embedded in the upper and lower surfaces of the slab, the movement of the slab will drive the movement of the tensile wires before being embedded, including pulling out from the coil bracket and subsequent straightening and tensioning.

[0036] The finished product processing unit includes an automatic cutting device, an edge treatment device for the board, a bottom reinforcement device, a top reinforcement device, a peripheral winding device, a surface treatment device, a conveying and distribution device, and a finished product curing device. The slab passes through all or part of the above devices in sequence and finally becomes a foam glass composite board. The finished product curing device is equipped with steam curing, ultraviolet curing, and infrared heating devices to meet the needs of hardening, curing, and drying of different reinforcement layers and decorative layers. The conveying and distribution device sends the surface-treated board into the finished product curing device through a lifting action and transports the final finished product to other places through a horizontal movement.

[0037] The automatic control unit is electrically connected to the meter, heating tube, temperature measuring instrument, temperature measuring rod, camera, wire breakage detection device, motor, fan, valve, pressurizing device, and other sensors and external power supplies. The control parameters include speed, temperature, length, height, angle, weight, flow rate, pressure, pressure intensity, current, voltage, and time to achieve the automation of production. The technical principles of the automatic control unit are as follows: First, the addition amounts of the components of the raw materials have a linear relationship with the heating temperature and heating rate, cooling temperature and cooling rate, and the linear speed of the drawn wire; Second, the pore structure of the foam glass is related to temperature, time, and raw material components.

[0038] The main unit of the automatic control unit is installed in the upper right corner of the steel frame. The temperature control module is installed on the outer side of the trough-shaped furnace wall and includes the time and voltage control parts of each heating tube. Other sensors also include pressure and temperature sensors in the feeding and pressurizing unit, temperature, air pressure, and water level sensors in the waste heat utilization device, thickness, length, displacement, temperature, and angle sensors in the finished product processing unit, and speed, angle, tension, and temperature sensors in the drawing and pulling unit.

[0039] The waste heat utilization device is mainly composed of coiled pipes made of copper or aluminum, which respectively absorb the heat of the gases discharged from the annealing chamber exhaust duct and the primary cooling chamber exhaust duct for primary heating. After the heat exchange, the gases are respectively discharged to the flue gas purification device through the left exhaust pipe and the right exhaust pipe and discharged from the chimney after purification treatment; the gases discharged from the exhaust pipe also pass through the flue gas purification device for purification and then are discharged from the chimney; the exhaust gas flow rates of the annealing chamber exhaust holes and the primary cooling chamber exhaust holes are respectively controlled by the valves, pressurizing devices, and the corresponding fans installed in the flue gas purification device.

[0040] The outer sides of the raw material tank and the elevator are wrapped with spiral heat exchange pipes, heat insulation layers, and protective layers from the inside to the outside. Among them, the heat exchange pipes and the water cooling pipes form a heat release and heat absorption device to preheat the powder in the raw material tank and the elevator.

[0041] Preferably, the normal allowable temperature of the furnace lining, heating tube, temperature measuring instrument, inner wall, board thickness control device, temperature measuring rod, camera, conveyor belt, high-temperature roller, and protective cover is 1200 °C.

[0042] Preferably, the heat insulation layer has a multi-layer structure, with a high-temperature resistant heat insulation material on the inner layer, a high-strength heat insulation material on the middle layer, and a heat insulation material with a small thermal conductivity and a low steam permeability coefficient on the outer layer.

[0043] Preferably, the heating temperatures of the first-stage heating, second-stage heating, third-stage heating, fourth-stage heating, and fifth-stage heating are determined according to the components of the raw materials and the pore requirements of the foam glass.

[0044] Preferably, after the furnace lining and the inner wall are installed, their inner surfaces are continuous, seamless, and smooth, with less resistance to the movement of the small conveyor belt and the slab.

[0045] Advantages of the present invention:

[0046] 1. Realize the moldless, continuous, simple, and automated production of foam glass;

[0047] 2. The continuous and full-length foam glass plates can be freely cut according to actual needs;

[0048] 3. Embed the tensile wire during the slab forming process, improving the mechanical properties of the foam glass plate;

[0049] 4. Realize the production of foam glass composite plates from raw materials to finishes in an assembly line manner;

[0050] 5. Efficient utilization of waste heat, energy-saving and environmental protection during the production process;

[0051] 6. Segmented heating, multi-point temperature control, and precise control in terms of time, speed, angle, displacement, pressure, etc., can not only ensure product quality but also improve production safety. Description of the Drawings

[0052] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0053] Figure 1 It is a schematic front view;

[0054] Figure 2 It is a schematic rear view;

[0055] Figure 3 It is a schematic left view;

[0056] Figure 4 It is a schematic cross-sectional view of the heating and foaming unit;

[0057] Figure 5Schematic diagram of longitudinal partial section and tensile wire arrangement;

[0058] Figure 6 Schematic diagram of longitudinal partial section and conveyor belt arrangement;

[0059] Figure 7 Schematic diagram of cooling exhaust gas and its waste heat utilization;

[0060] Figure 8 Schematic diagram of arrangement of cooling pipes at the lower part of horizontal cavity;

[0061] Figure 9 Cross-section schematic diagram, in which the left figure (a) is a schematic diagram of the horizontal cavity enclosed by a U-shaped cavity wall and a top cover, and the right figure (b) is a schematic diagram of the furnace chamber enclosed by a trough-shaped furnace wall and a straight furnace wall.

[0062] Marked in the figure as:

[0063] 1. Steel frame; 2. Mixed powder; 3. Tensile wire; 4. Slab; 5. Foam glass composite board; 6. Raw material tank; 7. Grinder; 8. Meter; 9. Delivery pipe; 10. Mixer; 11. Hoist; 12. Powder inlet; 13. Feed cavity; 14. Pushing rod; 15. Extrusion rod; 16. First exhaust pipe; 17. Cavity wall; 18. Furnace chamber; 19. Furnace liner; 20. Thermal insulation layer; 21. Outer shell; 22. Heating pipe; 23. Temperature measuring instrument; 24. Waste heat utilization device; 25. Inner wall; 26. Plate thickness control device; 27. Forming cavity; 28. Annealing cavity; 29. Primary cooling cavity; 30. Cooling cavity; 31. Slab outlet; 32. Partition; 33. Temperature measuring rod; 34. Camera; 35. Annealing cavity communication hole; 36. Annealing cavity exhaust hole; 37. Annealing cavity exhaust duct; 38. Primary cooling cavity communication hole; 39. Primary cooling cavity exhaust hole; 40. Primary cooling cavity exhaust duct; 41. Forming cavity air cooling pipe; 42. Annealing cavity air cooling pipe; 43. Primary cooling cavity air cooling pipe; 44. Water cooling pipe; 45. Traction roller group; 46. Conveyor belt; 47. Upper driving roller; 48. High-temperature roller; 49. Lower driving roller; 50. Lower driven roller; 51. Tension adjusting roller; 52. Upper driven roller; 53. Protective cover; 54. Coil support; 55. Arrangement guiding roller; 56. Tension straightening roller; 57. Broken wire detection device; 58. Steering roller; 59. Sleeve; 60. Pull-out roller; 61. Automatic cutting device; 62. Plate edge treatment device; 63. Bottom surface reinforcement device; 64. Top surface reinforcement device; 65. Peripheral winding device; 66. Surface treatment device; 67. Conveyor distribution device; 68. Finished product curing device; 69. Main machine; 70. Temperature control module; 71. Left exhaust pipe; 72. Right exhaust pipe; 73. Flue gas purification device; 74. Chimney. Specific implementation mode

[0064] To make the objectives, technical solutions, and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to specific embodiments and the accompanying drawings.

[0065] It should be noted that, unless otherwise defined, the technical terms or scientific terms used in the embodiments of the present invention should have the ordinary meanings understood by those of ordinary skill in the art to which the present disclosure pertains. The "first", "second", and similar terms used in the present disclosure do not denote any order, quantity, or importance, but are only used to distinguish different components. The terms such as "comprising" or "including" mean that the elements or items appearing before this term cover the elements or items listed after this term and their equivalents, without excluding other elements or items. The terms such as "connected" or "coupled" are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect. The terms such as "upper", "lower", "left", "right", etc. are only used to represent relative positional relationships, and when the absolute position of the object being described changes, the relative positional relationship may also change accordingly.

[0066] Please refer to Figures 1 to 9 and the description in the foregoing invention content, the present invention provides the following two embodiments: Embodiment 1

[0067] 600-type Foamed Glass Composite Board Production Line

[0068] Product specifications: Plate width B = 600 mm, plate thickness 50 - 300 mm, plate length 600 - 6000 mm, wire rod specifications φ0.5 - 4 mm, maximum foaming temperature 900 °C.

[0069] Main materials: The furnace liner 19, heating tubes 22, temperature measuring instruments 23, inner wall 25, plate thickness control device 26, temperature measuring rods 33, cameras 34, conveyor belts 46, high-temperature rollers 48, and shields 53 are made of 310S stainless steel; the outer shell 21, raw material tanks 6, water-cooled tubes 44, screw conveyors, and feed cavities 13 are made of 304 stainless steel; the air-cooled tubes and waste heat utilization devices 24 are made of aluminum alloy; the insulation layer 20 is composed of ceramic fiber insulation boards (1350 °C), foamed glass insulation boards (300 °C), and polyurethane insulation boards from the inside to the outside;

[0070] Manufacturing method: Step 1, process the steel frame 1 with galvanized steel and install it in place;

[0071] Step 2, process the outer shell 21 with a U-shaped cavity wall, with a length of 9300 mm, a width of 1000 mm, and a height of 600 mm, and install it on the steel frame 1. Then, install the bottom insulation layer 20, forming cavity air-cooled tubes 41, annealing cavity air-cooled tubes 42, primary cooling cavity air-cooled tubes 43, water-cooled tubes 44, and their valves and pressurizing devices, where the thickness of the insulation layer 20 is 200 mm, the same hereinafter;

[0072] Step 3: Process the inner wall 25 of the U-shaped cavity wall, which is 9000 mm long, 600 mm wide and 400 mm high, and install it in the center of the outer shell 21 and the insulation layer 20 in step 2, and ensure that the inner wall at the slab outlet 31 is flush with the outer shell 21;

[0073] Step 4: Process the furnace 19 of the trough-shaped furnace wall, which is 2200 mm high, 600 mm wide and 100 mm deep, and weld it to the inner wall 25. The inner weld is polished to form the main part of the L-shaped cavity with a width of 600 mm, a smooth interior and a continuous surface. Then install the insulation layer 20 and reserve installation holes for the heating tube 22, the temperature measuring instrument 23 and the high-temperature roller 48.

[0074] Step 5: Install the insulation layer 20, the temperature measuring rod 33, the camera 34, the annealing chamber connecting hole 35, and the primary cooling chamber connecting hole 38 on both sides of the U-shaped cavity wall, wherein the air outlet ends of the molding cavity air cooling pipe 41 and the annealing cavity air cooling pipe 42 are connected to the annealing cavity connecting hole 35, and the air outlet end of the primary cooling cavity air cooling pipe 43 is connected to the primary cooling cavity connecting hole 38;

[0075] Step 6: Process the outer shell 21 of the trough furnace wall to be 2400 mm high, 1000 mm wide and 300 mm deep, and cold weld and polish it with the outer shell 21 of the U-shaped cavity wall to form a continuous and beautiful L-shaped structure, and then fill the insulation layer 20;

[0076] Step 7: Make and install the traction roller group 45, the upper active roller 47, the high temperature roller 48, the lower active roller 49, the lower driven roller 50, the tension adjustment roller 51, the upper driven roller 52, the shield 53, the conveyor belt 46, the drive motor and the circuit, etc., and test and adjust them until they operate normally;

[0077] Step 8: Make and install the automatic cutting device 61, the plate edge processing device 62, the bottom surface reinforcement device 63, the top surface reinforcement device 64, the peripheral winding device 65, the surface processing device 66, the conveying and distributing device 67, and the finished product maintenance device 68, including the pull-out roller 60 and the water, electricity, and gas pipelines;

[0078] Step 9: Make and install the coil support 54, the arrangement guide roller 55, the tension straightening roller 56, the wire break detection device 57, the steering roller 58, the heating tube 22, the temperature meter 23, the sleeve 59, the temperature control module 70, the tensile wire 3, the sensor, the circuit, etc., and then test and adjust them until they operate normally;

[0079] Step 10: Make and install the raw material tank 6, grinder 7, meter 8, conveying pipe 9, mixer 10, elevator 11, powder inlet 12, feeding chamber 13, push rod 14, extrusion rod 15, exhaust pipe 16, as well as drive motor, sensor, circuit, etc., add raw materials, and test and adjust until it runs normally;

[0080] Step 11: Fabricate and install the flat furnace wall, including the furnace liner 19, plate thickness control device 26, waste heat utilization device 24, annealing chamber exhaust duct 37, primary cooling chamber exhaust duct 40, insulation layer 20, and outer shell 21, and test and adjust until normal operation. Among them, the furnace liner 19 is 1800 mm high and 640 mm wide, and the outer shell 21 is 1800 mm high and 1000 mm wide;

[0081] Step 12: Fabricate and install the top cover, including the inner wall 25, partition piece 32, annealing chamber exhaust hole 36, annealing chamber exhaust duct 37, primary cooling chamber exhaust hole 39, primary cooling chamber exhaust duct 40, insulation layer 20, and outer shell 21, and test and adjust. Among them, the inner wall 25 is 8800 mm long and 640 mm wide, and the outer shell 21 is 8800 mm long and 1000 mm wide;

[0082] Step 13: Fabricate, install, and commission the control unit and other parts of the entire equipment until normal operation. Among them, the automatic cutting device uses a diamond brazed saw blade with a diameter of 300 mm, the plate edge treatment device is a 100 mm angle grinder for chamfering the plate edge, the bottom reinforcement device and the top reinforcement device are rubber-coated rollers for laying fiberglass cloth, the peripheral winding device is a mechanism for winding fiberglass on the slab, the surface treatment device is a spray gun for spraying real stone paint, the conveying and distribution device is an automatically controlled flat battery car, and the finished product curing device is a drying oven.

[0083] Production process: First, load the powder raw materials into the raw material tank 6 according to regulations. Then, set the control unit according to the product requirements and relevant parameters determined by preliminary experiments. After that, start the automatic operation of the equipment: Each component of the powder raw materials successively completes grinding, metering, and mixing in the feeding and pressurizing unit to become the mixed powder 2, and then undergoes preheating, lifting, pushing, and pressurizing, and enters the heating and foaming unit together with the tensile wire 3. Then, it successively passes through the first-stage heating, second-stage heating, third-stage heating, fourth-stage heating, and fifth-stage heating to become a high-temperature foaming fluid, and then flows into the forming and cooling unit, and successively undergoes forming, annealing, primary cooling, and cooling to become a slab 4 with the tensile wire 3 evenly distributed on the upper and lower sides. Moreover, under the traction of the traction and pulling-out unit, it enters the finished product processing unit, and successively undergoes plate cutting, plate edge treatment, surface treatment, and finished product curing to become the foam glass composite board 5.

[0084] The working principle is described in the invention content. Embodiment 2

[0085] 1000-type foam glass composite board production line

[0086] The width of the plate B = 1000 mm. The outer shell 21 of the U-shaped cavity wall, the trough-shaped furnace wall, the top cover, and the flat furnace wall is 1400 mm wide. The inner wall 25 of the U-shaped cavity wall and the furnace liner 19 of the trough-shaped furnace wall are 1000 mm wide. The inner wall 25 of the top cover and the furnace liner 19 of the flat furnace wall are 1040 mm wide. Except for this, the rest of the content is the same as that of Embodiment 1.

[0087] Those of ordinary skill in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of the present disclosure (including the claims) is limited to these examples; under the concept of the present invention, the technical features in the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations in different aspects of the present invention as described above, which are not provided in detail for the sake of brevity.

[0088] The embodiments of the present invention are intended to cover all such substitutions, modifications, and variations that fall within the broad scope of the appended claims. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A production equipment for pultruded foam glass composite board, comprising a steel frame and a feeding and pressurizing unit, a heating and foaming unit, a forming and cooling unit, a finished product processing unit, a traction and pulling unit, and an automatic control unit which are installed on the steel frame, and is characterized in that: The production process of the foam glass composite board is as follows: after the components of the powder raw materials are ground and metered in sequence in the feeding and pressurizing unit, they are mixed together to form a mixed powder, and then lifted, pushed, and pressurized, and enter the heating and foaming unit together with the tensile wire. Then, it successively undergoes primary heating, secondary heating, tertiary heating, quaternary heating, and quinary heating. After becoming a high-temperature foaming fluid, it flows into the forming and cooling unit, and successively undergoes forming, annealing, primary cooling, and cooling to generate a slab with tensile wires uniformly distributed on the upper and lower sides and a width of B. Moreover, under the traction of the traction and pulling-out unit, the slab enters the finished product processing unit, and successively undergoes sheet cutting, plate edge treatment, surface treatment, and finished product curing to become the foam glass composite board. And the feeding and pressurizing unit, heating and foaming unit, forming and cooling unit, finished product processing unit, and traction and pulling-out unit are all controlled by the automatic control unit; the heating and foaming unit is vertically arranged, and the forming and cooling unit is horizontally arranged, and the two form an L-shaped structure, and its internal is an L-shaped cavity that is interconnected and heat-resistant; the pulling-extrusion method is a technical method that realizes pulling by using the traction and pulling-out unit, tensile wire, and wire distribution device, and realizes extrusion by using the feeding and pressurizing unit and the heating and foaming unit; The inside of the forming and cooling unit is a horizontal cavity with a rectangular cross-section whose length is equal to B; the inside of the heating and foaming unit is a furnace chamber with a rectangular plane whose length is equal to B; the horizontal cavity is communicated with the bottom of the furnace chamber and is separated by a plate thickness control device; the traction and pulling-out unit includes a traction roller group and a heat-resistant conveyor belt, and the upper driving roller, high-temperature roller, lower driving roller, lower driven roller, tension adjusting roller, and upper driven roller that the conveyor belt passes through in sequence; The wire distribution device is located on the left outer side of the heating and foaming unit, and the wire distribution device is fixed on the steel frame, and includes a coil bracket, arrangement guiding roller, tension straightening roller, broken wire detection device, and steering roller that the tensile wire passes through in sequence; the tensile wire is multiple wires of the same length and continuously wound into a coil. After passing through the steering roller, it moves upward along the surface of the conveyor belt, turns over the upper driving roller and then moves downward into the furnace chamber. Then, half of the wires pass under the high-temperature roller, enter the horizontal cavity, and are embedded in the lower part of the slab, and the other half of the wires pass under the sleeve and the plate thickness control device and are embedded in the upper part of the slab; at the initial stage of production and before the slab is formed, the tensile wire also needs to pass through the traction roller group and be fixed on the pulling-out roller, and is pulled and pulled out by it; the tensile wire moves with the slab, and the slab is formed on the conveyor belt and is successively pulled by the conveyor belt, traction roller group, and pulling-out roller; The finished product processing unit includes a slab automatic cutting device, plate edge treatment device, bottom surface reinforcement device, top surface reinforcement device, peripheral winding device, surface treatment device, conveying and distributing device, and finished product curing device. The slab is successively processed by the finished product processing unit and finally becomes the foam glass composite board.

2. The production equipment of a pultruded foam glass composite board according to claim 1, characterized in that: The feeding and pressurizing unit includes the raw material tanks for the respective powder raw materials, the grinders for the respective powder raw materials, the meters for the respective powder raw materials, as well as the conveying pipe, mixer, elevator, powder inlet, feeding chamber, pushing rod, extrusion rod through which the mixed powder passes in sequence, and also the first exhaust pipe, chamber wall and wire distribution device. Among them, the inlet and outlet of the grinder are respectively connected to the bottom of the raw material tank and the inlet of the meter, the inlet and outlet of the conveying pipe are respectively connected to the outlet of the meter and the inlet of the mixer, the inlet and outlet of the elevator are respectively connected to the outlet of the mixer and the powder inlet, the pushing rod is horizontally arranged at the bottom of the feeding chamber, dispersing and pushing the mixed powder towards the inlet of the extrusion rod. The pushing rod is a screw auger driven by a motor. The feeding chamber is located above the heating and foaming unit and is a cavity enclosed by the chamber wall. The conveying pipe, elevator and extrusion rod are all of the tubular screw conveyor structure, which is driven by a motor. Among them, the extrusion rod is vertically arranged. The upper end of the sleeve outside the tubular screw conveyor structure is flush with and fixed to the bottom plate of the feeding chamber, and the lower end is inserted into the heating and foaming unit. Its main shaft extends above the feeding chamber and is equipped with a gear.

3. The production equipment of a pultruded foam glass composite board according to claim 2, characterized in that: The furnace chamber is enclosed by the trough-shaped furnace wall on the left and the detachable flat furnace wall on the right, and from inside to outside are the furnace liner, heat insulation layer and outer shell in sequence. The extrusion rod and heating pipes are installed from top to bottom in sequence. The heating temperatures inside the furnace chamber from top to bottom are the first-stage heating temperature, second-stage heating temperature, third-stage heating temperature, fourth-stage heating temperature and fifth-stage heating temperature, and their corresponding heating temperatures are 60°C - 120°C, 240°C - 300°C, 420°C - 480°C, 600°C - 680°C, 750°C - 900°C respectively. Moreover, except for the first-stage heating, the rest are heated by the heating pipes. The heating pipes are multiple high-temperature-resistant electric heating pipes, located on the long axis of the rectangular plane, arranged in a form of one row with multiple columns, and a temperature measuring instrument is also provided beside each heating pipe. A waste heat utilization device is arranged outside the furnace chamber and below the feeding chamber. The first-stage heating is located inside the furnace chamber at the position of the extrusion rod and is heated by the waste heat utilization device arranged below the feeding chamber.

4. The production equipment of a pultruded foam glass composite board according to claim 3, characterized in that: The horizontal cavity is enclosed by the U-shaped chamber wall at the lower part and the detachable top cover at the upper part, and from inside to outside are the inner wall, heat insulation layer and outer shell in sequence. The horizontal cavity is communicated with the bottom of the furnace chamber and is separated by a plate thickness control device. Moreover, from left to right, it is equally divided into a forming cavity, annealing cavity, primary cooling cavity and cooling cavity in sequence, and its right end is the slab outlet. Among them, partition plates are provided between the annealing cavity and the forming cavity and the primary cooling cavity for separation. The partition plate has high elasticity, the upper part is fixed to the inner wall of the top cover, and the lower part inclines to the right to prevent gas from flowing into the chamber on the high-temperature side. The plate thickness control device is installed on the flat furnace wall and is driven by a motor to control the thickness of the slab. On the upper part of the side wall of the horizontal cavity, a plurality of temperature measuring rods extending into the cavity and high-temperature resistant cameras are arranged at intervals. On the upper part of the side wall at the high-temperature end of the annealing cavity, there is an annealing cavity communication hole, and on the top surface, there is an annealing cavity exhaust hole, and the gas in the cavity is discharged to the waste heat utilization device through the annealing cavity exhaust duct; on the upper part of the side wall at the high-temperature end of the primary cooling cavity, there is a primary cooling cavity communication hole, and on the top surface, there is a primary cooling cavity exhaust hole, and the gas in the cavity is discharged to the waste heat utilization device through the primary cooling cavity exhaust duct; the annealing cavity exhaust duct and the primary cooling cavity exhaust duct are arranged in the heat insulation layer of the top cover and the straight furnace wall; In the bottom heat insulation layers of the forming cavity, the annealing cavity, the primary cooling cavity, and the cooling cavity, there are respectively a forming cavity air cooling pipe, an annealing cavity air cooling pipe, a primary cooling cavity air cooling pipe, and a water cooling pipe. The inflow ends of the air cooling pipes and the water cooling pipes are respectively located on the low-temperature side of their corresponding chambers, and are respectively provided with valves and pressurizing devices; the outlet ends of the forming cavity air cooling pipe and the annealing cavity air cooling pipe are communicated with the annealing cavity communication hole, and the outlet end of the primary cooling cavity air cooling pipe is communicated with the primary cooling cavity communication hole.

5. The production equipment of a pultruded foam glass composite board according to claim 4, characterized in that: The upper driving roller is located above the trough-shaped furnace wall, the high-temperature roller is located at the inner corner of the L-shaped cavity, the lower driving roller is located at the lower outer side of the slab outlet, the lower driven roller is located outside the outer corner of the L-shaped structure, the upper driven roller is located directly above the lower driven roller, the tension adjusting roller is located between the upper driven roller and the lower driven roller. The upper driving roller and the lower driving roller are both driven by motors. The high-temperature roller is installed on the furnace linings on both sides through high-temperature resistant sealing rings and high-temperature resistant bearings, and is provided with a high-temperature resistant protective cover; The traction roller group is located on the right side of the slab outlet, and is composed of multiple rollers driven by motors. It is divided into upper and lower groups, and is pressed tightly against the upper and lower surfaces of the slab through a pressing mechanism and moves in the direction of pulling out the slab outward.

6. The production equipment of a pultruded foam glass composite board according to claim 1, characterized in that: The finished product curing device is equipped with steam curing, ultraviolet curing, and infrared heating devices. The conveying and distributing device sends the surface-treated sheet material into the finished product curing device through a lifting action and transports the finished product to other places through a horizontal movement.

7. The production equipment of a pultruded foam glass composite board according to claim 5, characterized in that: The automatic control unit is electrically connected to the meter, heating pipe, thermometer, temperature measuring rod, camera, wire break detection device, motor, fan, valve, pressurizing device, and other sensors and external power supplies. The controlled parameters include speed, temperature, length, height, angle, weight, flow rate, pressure, pressure intensity, current, voltage, and time; the other sensors include the pressure sensor and temperature sensor in the feeding and pressurizing unit, the temperature sensor, air pressure sensor, and water level sensor in the waste heat utilization device, the thickness sensor, length sensor, displacement sensor, temperature sensor, and angle sensor in the finished product processing unit, and the speed sensor, angle sensor, tension sensor, and temperature sensor in the traction and pulling out unit; the main unit of the automatic control unit is installed in the upper right corner of the steel frame; the temperature control module is installed outside the trough-shaped furnace wall to control the time and voltage of each heating pipe.

8. The production equipment of a pultruded foam glass composite board according to claim 7, characterized in that: The waste heat utilization device absorbs the heat of the gases discharged from the annealing chamber exhaust duct and the primary cooling chamber exhaust duct respectively, and discharges the gases to the flue gas purification device through the left exhaust pipe and the right exhaust pipe respectively; the first exhaust pipe also discharges the gas to the flue gas purification device; the flue gas purification device discharges the purified gas from the chimney; the exhaust gas flow rates of the annealing chamber exhaust hole and the primary cooling chamber exhaust hole are controlled by the valves arranged at the inflow end, the pressurizing device and the respective corresponding fans arranged in the flue gas purification device respectively; the outer sides of the raw material tank and the elevator are wrapped with heat exchange pipes, a heat insulation layer and a protective layer from the inside to the outside, wherein the heat exchange pipes and the water-cooled pipes form a heat release and heat absorption device to preheat the powder in the raw material tank and the elevator.

9. The production equipment of a pultruded foam glass composite board according to claim 5, characterized in that: The normal allowable temperatures of the furnace lining, heating pipes, temperature measuring instruments, inner wall, plate thickness control device, temperature measuring rod, camera, conveyor belt, high-temperature roller and protective cover are 1200 °C; the heat insulation layer is of a multi-layer structure, with a high-temperature resistant heat insulation material on the inner layer, a high-strength heat insulation material on the middle layer, and a heat insulation material with a small thermal conductivity and a low steam permeability coefficient on the outer layer; after the furnace lining and the inner wall are installed, the inner surfaces of the furnace lining and the inner wall are continuous, seamless and smooth.

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