Process for producing a ceramsite and polyurethane mixed precast member

Abstract

The application discloses a kind of ceramsite and polyurethane mixed prefabricated component production process, including step one, lay prefabricated mould box, lay prefabricated mould box on feeding assembly, and adjacent two prefabricated mould boxes are closely connected;Step two, mixed filler, sequentially set up storage bin, mixer and blanking assembly above production line, first feeding assembly is set in storage bin, and one feeding assembly is transported to mixer in the ceramsite in storage bin and is mixed, blanking assembly includes blanking bin, second feeding assembly and multiple spray heads, and multiple spray heads are sprayed polyurethane to the ceramsite of falling;Step three, lay decorative fabric, and extrude and fit decorative fabric on the upper surface of ceramsite-polyurethane mixture;Step four, fixed-length cutting;Step five, transport transfer.The process can produce arbitrary length prefabricated component, and the structural strength of prefabricated component is high, material mixing uniformity is good, process flow is simple and reliable, operation efficiency is high, and generalizability is strong.

Description

Technical Field

[0001] This invention relates to the field of building materials technology, specifically to a production process for precast components made from a mixture of ceramsite and polyurethane. Background Technology

[0002] The rapid development of high-rise and super high-rise buildings in my country's construction, bridge, railway, and water conservancy projects presents new challenges due to their inherent weight and span requirements, necessitating advanced prestressed concrete construction techniques. Against this backdrop, lightweight and high-strength expanded clay concrete (ECC) is gradually becoming a major trend in the application and development of concrete. ECC possesses excellent properties and significant characteristics, including lightweight, high strength, earthquake resistance, durability, fire resistance, sound insulation, thermal insulation, good workability, easy processing, and low cost, making it a high-performance inorganic green building material. However, current ECC preparation processes simply mix expanded clay with river sand. Since the density of expanded clay is lower than that of cement mortar, it tends to float during preparation, reducing the homogeneity of the concrete and even causing segregation, thus hindering its use and promotion. Patent application number 202010162553.2 discloses a precast ceramsite concrete panel integrating decoration and insulation, comprising a comb-shaped steel reinforcement frame, a ceramsite concrete layer, and an insulation layer. The ceramsite concrete layer is poured within the comb-shaped steel reinforcement frame, and the insulation layer is located above the ceramsite concrete layer. Several self-locking connectors are provided within the insulation layer, connecting the insulation layer and the ceramsite concrete layer. This panel features a patterned surface and decorative materials, with an internal insulation layer, and is cast into a single unit in one process, achieving integrated decoration and insulation. Furthermore, the smooth inner surface of the panel eliminates the need for a cement mortar leveling layer, fulfilling the design and construction requirements of the exterior wall in one step. This reduces multiple processes such as dry-hanging and pasting of decorative surfaces, exterior wall insulation, and wall plastering, saving construction costs. However, the manufacturing process of this panel is cumbersome, the structure is relatively complex, and the panel's overall regular shape makes assembly during construction difficult. Summary of the Invention

[0003] The purpose of this invention is to provide a production process for precast components made from a mixture of ceramsite and polyurethane. This process can produce precast components of any length, with high structural strength, good material mixing uniformity, a simple and reliable process flow, high operating efficiency, and strong scalability.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A production process for precast components made from a mixture of expanded clay aggregate and polyurethane, the production process comprising the following steps:

[0006] Step 1: Laying prefabricated mold boxes. Prefabricated mold boxes are laid on the feeding assembly, with adjacent prefabricated mold boxes closely connected. The feeding assembly consists of multiple sets of feeding conveyor shafts located at one end of the production line. The multiple sets of feeding conveyor shafts are powered by a feeding drive motor. The feeding assembly continuously conveys the prefabricated mold boxes onto the production line. The production line includes a bottom conveyor assembly and left and right conveyor assemblies located on both sides of the bottom conveyor assembly.

[0007] Step two, mixing the filler: A storage silo, a mixer, and a discharge assembly are sequentially arranged above the production line. A first conveying assembly is installed in the storage silo, which transports the ceramsite in the storage silo to the mixer. The mixer mixes the ceramsite and then transports the mixed ceramsite to the discharge assembly. The discharge assembly includes a discharge silo, a second conveying assembly located inside the discharge silo, and multiple nozzles located outside the discharge silo. The second conveying assembly transports the mixed ceramsite, which falls naturally from its end into the precast mold. Two nozzles are located on either side of the naturally falling ceramsite and spray polyurethane onto the falling ceramsite to form a ceramsite-polyurethane mixture. The mixed ceramsite-polyurethane mixture falls into the precast mold. By matching the transport speed of the production line with the flow rate of the nozzles and the amount of ceramsite falling, the filling amount in each precast mold meets the design value.

[0008] Step 3: Laying the decorative fabric. A roller support frame and an upper extrusion conveyor assembly are sequentially set above the production line. A roll of decorative fabric is rotatably installed on the roller support frame. One end of the decorative fabric wound on the roll of decorative fabric is attached to the surface of the ceramsite-polyurethane mixture via the upper extrusion conveyor assembly. When the upper extrusion conveyor assembly conveys the decorative fabric, it extrudes the decorative fabric and the ceramsite-polyurethane mixture.

[0009] Step four, fixed-length cutting: A cutting assembly is set at the other end of the production line. After the decorative fabric is laid, the expanded clay aggregate-polyurethane mixture solidifies. When cutting is required, the cutting assembly cuts the continuous length of the finished product formed in the previous process to a fixed length. The cutting assembly includes a synchronous conveying component, a cutting bracket mounted on the synchronous conveying component, a first linear drive component mounted on the cutting bracket, a cutting drive motor mounted on the first linear drive component, and a cutting blade powered by the cutting drive motor. The first linear drive component drives the cutting drive motor to reciprocate vertically, the cutting drive motor drives the cutting blade to rotate, and the synchronous conveying component drives the cutting bracket and the bottom conveying component to move forward synchronously.

[0010] Step 5, conveying and transfer: Multiple sets of conveying shafts are set on one side of the cutting component, and the multiple sets of conveying shafts continuously convey the cut products outward.

[0011] Preferably, in step one, the prefabricated mold box is a box-shaped structure with an open top, and mortise and tenon joints with matching shapes are provided on the left and right sides of the prefabricated mold box.

[0012] Preferably, in step two, the ceramsite particles in the storage silo have different diameters, and the ceramsite particles of different diameters are mixed in the mixer.

[0013] Preferably, in step two, the lateral distance between the left conveying component and the right conveying component relative to the bottom conveying component is adjustable to accommodate the conveying of prefabricated molds of different widths.

[0014] Preferably, in step two, the left conveying assembly and the right conveying assembly have the same structure. The left conveying assembly includes a lateral conveying shaft, a lateral drive motor, and a drive chain powered on the lateral conveying shaft. The lateral drive motor is poweredly connected to the lateral conveying shaft and drives the lateral conveying shaft to rotate. A chain plate is installed on the drive chain.

[0015] Preferably, in step three, two sets of decorative fabric rolls are installed on the roll support frame, and the two sets of decorative fabric rolls are fed sequentially.

[0016] Preferably, in step four, a clamping assembly for clamping a continuous length of finished product is provided on one side of the cutting assembly. The clamping assembly includes a base support, a bottom support roller rotatably mounted on the base support, a second linear drive component fixedly mounted on the base support, and a top support roller mounted on the second linear drive component. The continuous length of finished product passes between the bottom support roller and the top support roller.

[0017] Preferably, in step four, a tensioning wheel is installed on the roll support frame, and the decorative fabric is connected to the upper extrusion conveying assembly via the tensioning wheel.

[0018] In this invention, the production process includes laying precast molds, mixing fillers, laying decorative fabric, cutting to length, and conveying and transferring. The process is simple and reliable, enabling efficient production of precast components made from a mixture of expanded clay aggregate and polyurethane. The length, width, and thickness of these precast components can be adjusted to meet product requirements, resulting in strong product adaptability. During the mixing process, multiple nozzles spray from both sides of the naturally falling expanded clay aggregate, ensuring a more uniform mixture and guaranteeing product uniformity and structural strength reliability. A mixing machine further mixes the expanded clay aggregate, ensuring uniform mixing of aggregates of different diameters and improving the consistency of the product structure. The mortise and tenon joints on both sides of the precast molds facilitate the installation and connection of adjacent precast components, simplifying construction. Attached Figure Description

[0019] Figure 1 This is a schematic front view of the overall structure of the present invention;

[0020] Figure 2 This is a top view of the overall structure of the present invention;

[0021] Figure 3 This is a magnified schematic diagram of a partial structure of the present invention;

[0022] Figure 4 This is a schematic diagram of the mixing state of the sprayed material according to the present invention;

[0023] Figure 5 This is a schematic diagram of the cutting component structure of the present invention;

[0024] Figure 6 This is a schematic diagram of the clamping component structure of the present invention;

[0025] Figure 7 This is a schematic diagram of the prefabricated mold box structure of the present invention;

[0026] In the diagram: 1. Precast mold box; 2. Feeding assembly; 3. Production line; 4. Storage silo; 5. Mixer; 6. Drop assembly; 7. First conveying assembly; 8. Decorative fabric; 9. Roll support frame; 10. Upper extrusion conveyor assembly; 11. Decorative fabric roll; 12. Tensioning wheel; 13. Cutting assembly; 14. Clamping assembly; 15. Conveying shaft; 30. Bottom conveying assembly; 31. Left side conveying assembly; 32. Right side conveying assembly; 33. Lateral conveying shaft; 34. Lateral drive motor; 35. Drive chain; 36. Chain plate; 60. Drop silo; 61. Second conveying assembly; 62. Nozzle; 130. Synchronous conveying component; 131. Cutting bracket; 132. First linear drive component; 133. Cutting drive motor; 134. Cutting blade; 140. Base support; 141. Bottom support roller; 142. Second linear drive component; 143. Top support roller. Detailed Implementation

[0027] The present invention will be further described below with reference to the accompanying drawings:

[0028] like Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 and Figure 7 The process shown is a production process for precast components made from a mixture of expanded clay and polyurethane, which includes the following steps:

[0029] Step 1: Laying prefabricated mold boxes 1. Prefabricated mold boxes 1 are laid on the feeding assembly 2, with adjacent prefabricated mold boxes 1 tightly connected. The connected prefabricated mold boxes 1 pass through the entire production line 3 from one end of the feeding assembly 2, and the feeding assembly 2 conveys the prefabricated mold boxes 1 to the production line 3. In one embodiment, the prefabricated mold box 1 is a box-shaped structure with an open top. Matching mortise and tenon joints are provided on the left and right sides of the prefabricated mold box 1. During installation, the manufactured products can be quickly connected through these mortise and tenon joints, improving the reliability of the product connection. Specifically, a square root-shaped overlapping portion is provided at the front end of the prefabricated mold box 1, and a hook-shaped overlapping portion is provided at the rear end of the prefabricated mold box 1. The square root-shaped overlapping portion overlaps the hook-shaped overlapping portion, ensuring that adjacent prefabricated mold boxes 1 are tightly connected.

[0030] The feeding assembly 2 consists of multiple feeding conveyor shafts located at one end of the production line 3. The multiple feeding conveyor shafts are powered by a feeding drive motor (not shown in the figure) and are powered by a chain drive component. Driven by the feeding drive motor, the multiple feeding conveyor shafts rotate synchronously and move forward to convey the precast mold box 1. The feeding assembly 2 continuously conveys the precast mold box 1 to the production line 3.

[0031] Production line 3 includes a bottom conveyor assembly 30 and a left conveyor assembly 31 and a right conveyor assembly 32 disposed on both sides of the bottom conveyor assembly 30. The lateral distance between the left and right conveyor assemblies 31 and 32 relative to the bottom conveyor assembly 30 is adjustable to accommodate the conveying of prefabricated mold boxes 1 of different widths. The bottom conveyor assembly 30, left conveyor assembly 31, and right conveyor assembly 32 have the same structure. Both the left and right conveyor assemblies 31 and 32 include a lateral conveyor shaft 33, a lateral drive motor 34, and a drive chain 35 powered by the lateral conveyor shaft 33. The lateral drive motor 34 is powered by the lateral conveyor shaft 33 and drives two or more lateral conveyor shafts 33 to rotate. Chain plates 36 are fixedly mounted on the drive chain 35 by fasteners. The top of the chain plates 36 is flush with the top of the bottom conveyor assembly 30, and the bottom sides of the prefabricated mold box 1 are disposed on the chain plates 36. The bottom conveyor assembly 30 has the same structure as the left conveyor assembly 31, but the chain plates 36 are not installed on the bottom conveyor assembly 30. The left conveying component 31 and the right conveying component 32 are installed on both sides of the bottom conveying component 30 by adjusting brackets, and the positions of the left conveying component 31 and the right conveying component 32 can be adjusted by adjusting the brackets.

[0032] Step two, mixing the filler: Above production line 3, a storage silo 4, a mixer 5, and a discharge assembly 6 are sequentially installed via mounting brackets. A first conveyor assembly 7 (a conveyor belt structure) is installed inside the storage silo 4, conveying the ceramsite from the storage silo 4 to the mixer 5. The mixer 5 mixes the ceramsite and then conveys the mixed ceramsite to the discharge assembly 6. The ceramsite in the storage silo 4 has a different diameter; ceramsite of different diameters is mixed in the mixer 5. During operation, ceramsite of different diameters is placed in the storage silo 4 according to product requirements. A funnel-shaped opening is provided at the top of the storage silo 4 for easy addition of ceramsite.

[0033] The material feeding assembly 6 includes a material feeding bin 60, a second material conveying assembly 61 disposed within the material feeding bin 60, and multiple nozzles 62 fixed to the outside of the material feeding bin 60 by fasteners. The second material conveying assembly 61 is an upwardly inclined conveyor belt structure that transports the mixed ceramsite and allows it to fall naturally from its end into the precast mold box 1. The width of the conveyor belt in the second material conveying assembly 61 is slightly smaller than the width of the inner cavity of the precast mold box 1. The multiple nozzles 62 are located on both sides of the naturally falling ceramsite and spray polyurethane onto the falling ceramsite to form a ceramsite-polyurethane mixture. The mixed ceramsite-polyurethane mixture falls into the precast mold box 1. The nozzles 62 are connected to a material pump through a material conveying pipe, and the material pump pumps the polyurethane solution into the material conveying pipe for spraying through the nozzles 62. One nozzle 62 sprays from the precast mold 1 to the naturally falling ceramic particles, while another nozzle 62 sprays from the naturally falling ceramic particles to the precast mold 1. Multiple nozzles 62 spray the falling ceramic particles. By matching the transport speed of the production line 3 with the flow rate of the nozzles 62 and the amount of falling ceramic particles, the filling amount in each precast mold 1 meets the design value.

[0034] Step 3: Laying the decorative fabric 8. Above production line 3, a roller support frame 9 and an upper extrusion conveyor assembly 10 are sequentially installed via a support structure. A decorative fabric roll 11 is rotatably mounted on the roller support frame 9 via a rotating shaft. One end of the decorative fabric wound on the roll 11 is bonded to the surface of the ceramsite-polyurethane mixture via the upper extrusion conveyor assembly 10. As the upper extrusion conveyor assembly 10 conveys the decorative fabric, it extrudes the decorative fabric 8 and the ceramsite-polyurethane mixture, tightly bonding them together. In one embodiment, two sets of decorative fabric rolls 11 are installed on the roller support frame 9. The two sets of decorative fabric rolls 11 are fed sequentially, meaning that after one set of decorative fabric rolls 11 is used, another set can be quickly installed, avoiding the problem of reduced production efficiency due to changing the decorative fabric rolls 11. A tensioning wheel 12 is installed on the roller support frame 9, and the decorative fabric 8 is connected to the upper extrusion conveyor assembly 10 via the tensioning wheel 12. The tensioning wheel 12 straightens and tensions the decorative fabric 8, ensuring product quality.

[0035] Step four, fixed-length cutting: A cutting component 13 is installed at the other end of production line 3. After the decorative fabric is laid, the ceramsite-polyurethane mixture solidifies. Polyurethane typically solidifies within 3-5 minutes. When cutting is required, the cutting component 13 performs fixed-length cutting on the continuous length of the finished product formed in the previous process. The cutting length is determined according to the conveying speed of production line 3, achieving the purpose of producing products of different lengths. Specifically, when a flush end is required, the prefabricated mold 1 filled with the ceramsite-polyurethane mixture needs to be cut to form a neat end face. When cutting is not required, the cutting component 13 does not perform cutting operations.

[0036] The cutting assembly 13 includes a synchronous conveying component 130, a cutting bracket 131 mounted on the synchronous conveying component 130, a first linear drive component 132 mounted on the cutting bracket 131, a cutting drive motor 133 mounted on the first linear drive component 132, and a cutting blade 134 powered by the cutting drive motor 133. The first linear drive component 132 drives the cutting drive motor 133 to reciprocate vertically, and the cutting drive motor 133 drives the cutting blade 134 to rotate and perform cutting operations. The synchronous conveying component 130 drives the cutting bracket 131 and the bottom conveying assembly 30 to move forward synchronously. The synchronous conveying component 130 consists of a fixed bracket, a lead screw motor mounted on the fixed bracket, a lead screw nut mounted on the lead screw motor, and a sliding bracket mounted on the lead screw nut. A slide rail and a slider assembly are also installed on the sliding bracket and the fixed bracket. The cutting bracket 131 is fixedly mounted on the sliding bracket and performs linear reciprocating operations under the drive of the lead screw motor and the lead screw nut. The lead screw motor is a stepper motor, which controls the synchronous conveying component 130 and the bottom conveying assembly 30 to move forward synchronously. The diameter of the cutting blade 134 is larger than the width of the precast mold box 1. In a preferred embodiment, the first linear drive component 132 is mounted on a horizontal guide rail via a slider. The horizontal guide rail is mounted on the cutting bracket 131. An electric push rod, a pneumatic cylinder, or a hydraulic cylinder is also mounted on the cutting bracket 131. The output end of the electric push rod, pneumatic cylinder, or hydraulic cylinder is connected to the slider. The electric push rod, pneumatic cylinder, or hydraulic cylinder drives the first linear drive component 132 to move horizontally for cutting.

[0037] A clamping assembly 14 for holding continuous lengths of finished products is provided on one side of the cutting assembly 13. The clamping assembly 14 includes a base support 140, a bottom support roller 141 rotatably mounted on the base support 140 via a rotating shaft, a second linear drive component 142 fixedly mounted on the base support 140, and a top support roller 143 mounted on the second linear drive component 142 via an inverted U-shaped bracket. The continuous length of finished products passes between the bottom support roller 141 and the top support roller 143. The gap between the bottom support roller 141 and the top support roller 143 is adjusted by the second linear drive component 142 to accommodate products of different thicknesses. The clamping assembly 14 and the upper extrusion conveying assembly 10 clamp the finished products from both ends, ensuring stability during the cutting operation, avoiding uneven cut ends that affect the aesthetics and quality of the product, and improving the yield. A guide post is slidably mounted on the base support 140, with one end of the guide post mounted on the inverted U-shaped bracket to ensure the stability of the vertical movement of the top support roller 143.

[0038] Step 5, conveying and transferring: On the other side of the cutting component 13 and the clamping component 14, there are multiple sets of material conveying shafts 15. The multiple sets of material conveying shafts 15 continuously convey the cut products outward. The cut products are then handled and stacked by manual labor or robotic arms to complete the overall product manufacturing process.

[0039] The above embodiments are merely illustrative of the concept and implementation of the present invention and are not intended to limit it. Under the concept of the present invention, technical solutions without substantial changes are still within the scope of protection.

Claims

1. A production process for precast components made from a mixture of ceramsite and polyurethane, characterized in that: The production process includes the following steps: Step 1: Laying prefabricated mold boxes. Prefabricated mold boxes are laid on the feeding assembly, with adjacent prefabricated mold boxes closely connected. The feeding assembly consists of multiple sets of feeding conveyor shafts located at one end of the production line. The multiple sets of feeding conveyor shafts are powered by a feeding drive motor. The feeding assembly continuously conveys the prefabricated mold boxes onto the production line. The production line includes a bottom conveyor assembly and left and right conveyor assemblies located on both sides of the bottom conveyor assembly. Step two, mixing the filler: A storage silo, a mixer, and a discharge assembly are sequentially arranged above the production line. A first conveying assembly is installed in the storage silo, which transports the ceramsite in the storage silo to the mixer. The mixer mixes the ceramsite and then transports the mixed ceramsite to the discharge assembly. The discharge assembly includes a discharge silo, a second conveying assembly located inside the discharge silo, and multiple nozzles located outside the discharge silo. The second conveying assembly transports the mixed ceramsite, which falls naturally from its end into the precast mold. Two nozzles are located on either side of the naturally falling ceramsite and spray polyurethane onto the falling ceramsite to form a ceramsite-polyurethane mixture. The mixed ceramsite-polyurethane mixture falls into the precast mold. By matching the transport speed of the production line with the flow rate of the nozzles and the amount of ceramsite falling, the filling amount in each precast mold meets the design value. Step 3: Laying the decorative fabric. A roller support frame and an upper extrusion conveyor assembly are sequentially set above the production line. A roll of decorative fabric is rotatably installed on the roller support frame. One end of the decorative fabric wound on the roll of decorative fabric is attached to the surface of the ceramsite-polyurethane mixture via the upper extrusion conveyor assembly. When the upper extrusion conveyor assembly conveys the decorative fabric, it extrudes the decorative fabric and the ceramsite-polyurethane mixture. Step four, fixed-length cutting: A cutting assembly is set at the other end of the production line. After the decorative fabric is laid, the expanded clay aggregate-polyurethane mixture solidifies. When cutting is required, the cutting assembly cuts the continuous length of the finished product formed in the previous process to a fixed length. The cutting assembly includes a synchronous conveying component, a cutting bracket mounted on the synchronous conveying component, a first linear drive component mounted on the cutting bracket, a cutting drive motor mounted on the first linear drive component, and a cutting blade powered by the cutting drive motor. The first linear drive component drives the cutting drive motor to reciprocate vertically, the cutting drive motor drives the cutting blade to rotate, and the synchronous conveying component drives the cutting bracket and the bottom conveying component to move forward synchronously. Step 5, conveying and transfer: Multiple sets of conveying shafts are set on one side of the cutting component, and the multiple sets of conveying shafts continuously convey the cut products outward.

2. The production process of precast components made from a mixture of ceramsite and polyurethane according to claim 1, characterized in that: In step one, the prefabricated mold box is a box-shaped structure with an open top, and mortise and tenon joints with matching shapes are provided on the left and right sides of the prefabricated mold box.

3. The production process of precast components made from a mixture of ceramsite and polyurethane according to claim 1 or 2, characterized in that: In step two, the ceramsite particles with different diameters are placed in the storage silo, and the ceramsite particles with different diameters are mixed in the mixer.

4. The production process of precast components made from a mixture of ceramsite and polyurethane according to claim 1, characterized in that: In step two, the lateral distance between the left and right conveying components and the bottom conveying component is adjustable to accommodate the conveying of prefabricated molds of different widths.

5. The production process of precast components made from a mixture of ceramsite and polyurethane according to claim 1 or 4, characterized in that: In step two, the left conveying assembly and the right conveying assembly have the same structure. The left conveying assembly includes a lateral conveying shaft, a lateral drive motor, and a drive chain powered on the lateral conveying shaft. The lateral drive motor is poweredly connected to the lateral conveying shaft and drives the lateral conveying shaft to rotate. A chain plate is installed on the drive chain.

6. The production process of precast components made from a mixture of ceramsite and polyurethane according to claim 1, characterized in that: In step three, two sets of decorative fabric rolls are installed on the roll support frame, and the two sets of decorative fabric rolls are fed in sequence.

7. The production process of precast components made from a mixture of ceramsite and polyurethane according to claim 1, 2, 4 or 6, characterized in that: In step four, a clamping assembly for clamping a continuous length of finished product is provided on one side of the cutting assembly. The clamping assembly includes a base support, a bottom support roller rotatably mounted on the base support, a second linear drive component fixedly mounted on the base support, and a top support roller mounted on the second linear drive component. The continuous length of finished product passes between the bottom support roller and the top support roller.

8. The production process of precast components made from a mixture of ceramsite and polyurethane according to claim 1, characterized in that: In step four, a tensioning wheel is installed on the roll support frame, and the decorative fabric is connected to the upper extrusion conveyor assembly via the tensioning wheel.

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