Environment-friendly high-strength granite-imitated ultra-thick brick and preparation method thereof

Abstract

The application discloses an environment-friendly high-strength granite-imitated super-thick brick and a preparation method thereof. The brick comprises 5-30 parts of clay, 5-60 parts of aluminum ash, 1-20 parts of sand-shaped brick slag waste, 1-20 parts of sand-shaped granite slag waste and 1-20 parts of sand-shaped glass slag waste. The thickness of the brick is 30-60 mm, and the water absorption rate is 2-8%. The environment-friendly high-strength granite-imitated super-thick brick utilizes the gap between the sand-shaped waste and the clay, so that the green body has a good exhaust passage during the sintering process, thereby avoiding the technical problem that the green body is too thick, the bubbles cannot be exhausted, and product defects such as black core, bubbles and collapse are easily formed. Meanwhile, the aluminum ash contains a large amount of aluminum oxide, silicon dioxide and magnesium oxide and other substances, and forms a super-high-strength composite crystal phase system with other waste and clay, so that the product has high compressive and destructive strength, is not easy to break, maintenance cost is reduced, and the service life of the product is prolonged.

Description

Technical Field

[0001] This invention relates to the field of building ceramics technology, and in particular to an environmentally friendly, high-strength, imitation granite ultra-thick brick and its preparation method. Background Technology

[0002] Parking lot surfaces are typically paved with paving stones, cement, 15mm landscape ceramic bricks, sintered ceramic bricks, etc. In hot weather and rain, the bricks are prone to peeling due to thermal expansion and contraction. Furthermore, because the bricks are not thick enough, when a car drives over the edge of the bricks, the centrifugal force can cause the bricks to flip over and break easily, requiring replacement at certain intervals, resulting in high maintenance costs. Granite has a better texture and is also used for paving, but even 20mm granite bricks are prone to breakage in parking lot sections, and granite bricks are relatively expensive.

[0003] Currently, commercially available ultra-thick through-body ceramic tiles are less than 20mm thick, which cannot meet the needs of parking lot floor tiles. Although some existing technologies disclose ultra-thick through-body ceramic tiles with a thickness of up to 25mm and a compressive strength of 43-56Mpa, the low water absorption rate of these products means that further production of thicker tiles still faces the technical problem of "difficulty in complete sintering due to the greater thickness." This results in higher firing costs when producing tiles thicker than 25mm, requiring lower firing temperatures and longer sintering times. Similarly, tiles thinner than 25mm suffer from issues such as "excessive heat and rain causing the tiles to peel due to thermal expansion and contraction, and the thinness making them prone to tipping over and breaking due to centrifugal force when vehicles drive over their edges, requiring frequent replacement and incurring high maintenance costs." Currently, there are no reported cases of successful development of ultra-thick tiles thicker than 25mm in existing literature. Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, one of the objectives of this invention is to provide an environmentally friendly, high-strength, imitation granite ultra-thick brick that solves one or more technical problems existing in the prior art. It has a thickness of more than 25mm and has ultra-high strength, which can meet the harsh requirements of outdoor weather such as heat and rain without easily turning over or being crushed.

[0005] The second objective of this invention is to provide a method for preparing environmentally friendly, high-strength, granite-like ultra-thick bricks, which, while maintaining a constant sintering temperature, has a shorter sintering time and does not incur high firing costs.

[0006] One of the objectives of this invention is achieved through the following technical solution:

[0007] An environmentally friendly, high-strength, granite-like ultra-thick brick comprises the following components in parts by weight:

[0008] 5-30 parts clay, 5-60 parts aluminum ash, 1-20 parts sandy brick slag waste, 1-20 parts sandy granite slag waste, and 1-20 parts sandy glass slag waste.

[0009] The environmentally friendly, high-strength, imitation granite ultra-thick bricks have a thickness of 30mm-60mm and a water absorption rate of 2%-8%.

[0010] Specifically, the environmentally friendly, high-strength, ultra-thick imitation granite brick of this invention utilizes the particle size differences of environmentally friendly materials such as aluminum ash, sandy brick slag waste, sandy granite slag waste, and sandy glass slag waste. Combined with the bridging effect of clay, this allows different sandy waste materials to form gaps during mixing, reserving ample ventilation channels for the brick body. This avoids technical problems during sintering such as "the brick body being too thick, preventing air bubbles from escaping, easily leading to black cores, bubbles, collapse, and other product defects." Simultaneously, the aluminum ash contains a large amount of alumina, silicon dioxide, and magnesium oxide, which, through interaction with other waste materials and clay, form ultra-high-strength Al2O3, MgO, and SiO2 crystal phase systems, forming single or multiple composite crystal phase systems. This gives the product sufficiently high compressive and destructive strength, making it less prone to breakage. Furthermore, because the brick thickness is approximately 1.5-2 times that of ordinary paving stones, it avoids the problem of bricks quickly loosening and flipping due to tire grip during vehicle traffic, reducing maintenance costs and extending the product's service life.

[0011] Furthermore, the environmentally friendly, high-strength, imitation granite ultra-thick brick comprises the following components in parts by weight:

[0012] 20-30 parts clay, 30-50 parts aluminum ash, 3-10 parts sandy brick slag waste, 2-6 parts sandy granite slag waste, and 5-15 parts sandy glass slag waste.

[0013] Furthermore, the main chemical composition of the clay includes the following components by weight percentage:

[0014] The composition is as follows: SiO2 40%-50%, Al2O3 40%-45%, Fe2O3 0.1%-0.5%, CaO 0.1%-0.5%, MgO 0.1%-0.5%, K2O 0.01%-0.1%, Na2O 0.01%-0.1%, TiO2 0.01%-0.1%, with the remainder being water of crystallization.

[0015] Furthermore, the main chemical composition of the aluminum ash includes the following components by weight percentage:

[0016] Al2O3 70%-85%, SiO2 12%-20%, MgO 4.5%-10%, MnO 0%-0.1% (including zero), ZnO 0%-0.1% (including zero), CaO 0%-0.1% (including zero).

[0017] Furthermore, the mass ratio of Al2O3, SiO2, and MgO in the aluminum ash is 80:(12-13):(5-8). Because the aluminum ash has a powder structure, it is easily dispersed in the various sandy waste materials during stirring, promoting the formation of crystalline phase systems between waste materials and between waste materials and clay, enabling the product to achieve ultra-high strength. The average particle size of the aluminum ash is 8μm-15μm.

[0018] Furthermore, the main chemical composition of the sandy brick slag waste includes the following components by weight percentage:

[0019] The composition of the waste material is as follows: CaSiO3 80%-90%, SiO2 5%-10%, Al2O3 5%-10%, Fe2O3 0.1%-0.5%, CaO 0.1%-0.5%, Cr2O3 0%-0.1% (including zero), ZrO2 0%-0.1% (including zero). The sandy brick slag waste is mainly produced by crushing dismantled building materials into a sandy state using equipment. The average particle size of the sandy brick slag waste is 0.1mm-1mm, preferably 0.1mm-0.4mm. Because the sandy brick slag waste contains a large amount of CaSiO3, after sintering, it can prevent the system from agglomerating, clumping, or accumulating, and improve the fluidity of the system.

[0020] Furthermore, the sandy granite slag waste comprises the following components by weight percentage:

[0021] SiO2 65%-85%, mica 5%-15%, feldspar 2%-20%.

[0022] Mica is mainly composed of KAl2(AlSi3O) 10 (OH)2, feldspar is a solid solution composed of three feldspar end-member molecules: potassium feldspar (KAlSiO8), sodium feldspar (NaAlSi3O8), and calcium feldspar (CaAl2Si2O8). Due to the three-dimensional crystal structure of components such as mica and feldspar, the crystal structure changes from disorder to order during sintering, thus maintaining air venting channels in the system. After sintering, it still has sufficient microporous structure. The average particle size of the sandy granite slag waste is 0.1mm-1mm, preferably 0.4mm-0.6mm.

[0023] Furthermore, the main chemical composition of the sand-like glass slag waste includes the following components by weight percentage:

[0024] SiO260%-75%, Na2SiO310%-15%, CaSiO35%-15%, Al2O33%-6%, MnO1%-4%.

[0025] The average particle size of the sandy glass slag waste is 0.1mm-1mm, preferably 0.6mm-1mm.

[0026] Furthermore, the environmentally friendly, high-strength, granite-like ultra-thick brick also includes the following components in parts by weight:

[0027] 2-5 parts binder; 2-5 parts flux; 2-5 parts ceramic particles.

[0028] The binder is one or more of sodium carboxymethyl cellulose, sodium tripolyphosphate, aluminum dihydrogen phosphate, and sodium hexametaphosphate; the flux is one or more of potassium oxide, sodium oxide, calcium oxide, and magnesium oxide; the ceramic particles are granular objects made of ceramic materials (such as silicon oxide, aluminum oxide, potassium oxide, sodium oxide, calcium oxide, magnesium oxide, iron oxide, titanium oxide, etc.), and the average particle size of the ceramic particles is 0.1 mm to 1 mm.

[0029] The second objective of this invention is achieved by the following technical solution:

[0030] A method for preparing environmentally friendly, high-strength, granite-like ultra-thick bricks includes the following preparation steps:

[0031] S1: Clay is wet-milled into a slurry to obtain clay slurry; brick slag waste, granite slag waste, and glass slag waste are respectively processed into sand-like materials by sand-making equipment to obtain sand-like brick slag waste, sand-like granite slag waste, and sand-like glass slag waste.

[0032] S2: Clay slurry is mixed with sandy brick slag waste, sandy granite slag waste, sandy glass slag waste, aluminum ash, binder, flux, and ceramic particles. After the mixture is uniform, it is pressed into shape by pressing equipment to obtain the initial thick brick blank.

[0033] S3: The initial thick brick blank is dried, sprayed with slip, inkjet decorated with granite patterns, sprayed with colored dry granules / glaze, and finally placed in a firing furnace for sintering at a temperature of 750℃-1200℃ (preferably 1150℃-1200℃) for a time of 65min-90min (preferably 65min-85min). After cooling, the brick is obtained.

[0034] The process involves spraying colored dry granules to create a textured surface on the thick brick body, serving as decoration and protecting the underlying inkjet pattern. After cooling, the granules are polished / roughly ground to enhance their texture. In the sintering process, firing is performed according to a firing profile to control the relationship between firing temperature and time, thereby controlling the degree of vitrification and improving strength. Specifically, the firing profile is as follows: first, 750℃-850℃ for 5-10 minutes; then, 900℃-1000℃ for 10-20 minutes; and finally, 1150℃-1200℃ for 50-65 minutes.

[0035] Furthermore, the thickness of the environmentally friendly, high-strength imitation granite ultra-thick brick is 30mm-60mm, the water absorption rate is 2%-8%, the compressive strength is greater than 55Mpa, and the breaking strength can reach more than 20000nN.

[0036] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0037] 1. The environmentally friendly, high-strength, ultra-thick imitation granite brick of this invention utilizes the particle size differences of environmentally friendly materials such as aluminum ash, sandy brick slag waste, sandy granite slag waste, and sandy glass slag waste. Combined with the bridging effect of clay, this allows different sandy waste materials to form gaps during mixing, reserving ample ventilation channels for the brick body. This avoids technical problems during sintering such as "the brick body being too thick, preventing air bubbles from escaping, easily leading to black cores, bubbles, collapse, and other product defects." Simultaneously, the aluminum ash contains a large amount of alumina, silicon dioxide, and magnesium oxide, which, through interaction with other waste materials and clay, form ultra-high-strength Al2O3, MgO, and SiO2 crystal phase systems, forming single or multiple composite crystal phase systems. This gives the product sufficiently high compressive and destructive strength, making it less prone to breakage. Furthermore, because the brick thickness is approximately 1.5-2 times that of ordinary paving stones, it avoids the problem of bricks quickly loosening and flipping due to tire grip during vehicle traffic, reducing maintenance costs and extending the product's service life.

[0038] 2. The environmentally friendly, high-strength, imitation granite ultra-thick brick of this invention has a thickness exceeding 30mm, reaching 60mm, replacing conventional paving materials. It meets both the compressive strength requirements and the appearance and texture requirements of paving bricks. The use of environmentally friendly materials reduces the cost of producing ultra-thick bricks, while overcoming the obvious negative problems brought about by environmentally friendly materials during the firing process, such as bubbles, impurities generated by the reaction, and the impact on strength. When used outdoors, it retains a certain water absorption rate of 2%-8% while meeting the compressive strength requirements, which can achieve a certain effect of preventing water accumulation and slipping in rainy weather. Attached Figure Description

[0039] Figure 1 This is a schematic diagram of the structure of the environmentally friendly, high-strength, imitation granite ultra-thick brick in Example 1;

[0040] Figure 2 This is a schematic diagram of the structure of the environmentally friendly, high-strength, imitation granite ultra-thick brick in Example 2;

[0041] Figure 3 This is a schematic diagram of the side structure of the environmentally friendly, high-strength, imitation granite ultra-thick brick of Example 4.

[0042] Figure 4 This is a schematic diagram of the flat structure of the environmentally friendly, high-strength, imitation granite ultra-thick brick of Example 4. Detailed Implementation

[0043] The present invention will now be further described in conjunction with specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.

[0044] Example 1

[0045] An environmentally friendly, high-strength, granite-like ultra-thick brick comprises the following components in parts by weight:

[0046] 10 parts clay, 5 parts aluminum ash, 1 part sandy brick slag waste, 3 parts sandy granite slag waste, and 5 parts sandy glass slag waste.

[0047] The average particle size of the sandy brick slag waste is 0.4 mm; the average particle size of the sandy granite slag waste is 0.5 mm; and the average particle size of the sandy glass slag waste is 0.8 mm.

[0048] The main chemical composition of clay includes the following components by weight percentage:

[0049] The composition is as follows: SiO2 50%, Al2O3 42%, Fe2O3 0.1%, CaO 0.2%, MgO 0.2%, K2O 0.01%, Na2O 0.01%, TiO2 0.01%, with the remainder being water of crystallization.

[0050] The main chemical composition of aluminum ash includes the following components by weight percentage:

[0051] Al2O380%, SiO212%, MgO 8%.

[0052] The main chemical composition of sandy brick slag waste includes the following components by weight percentage:

[0053] CaSiO389.7%, SiO25%, Al2O35%, Fe2O30.2%, CaO 0.1%.

[0054] The sandy granite slag waste comprises the following components by weight percentage:

[0055] SiO2 75%, mica 8%, feldspar 17%.

[0056] The main chemical composition of sandy glass slag waste includes the following components by weight percentage:

[0057] SiO275%, Na2SiO310%, CaSiO35%, Al2O36%, MnO 4%.

[0058] It is prepared using the following steps:

[0059] S1: Clay is wet-milled into a slurry to obtain clay slurry; brick slag waste, granite slag waste, and glass slag waste are respectively processed into sand-like materials by sand-making equipment to obtain sand-like brick slag waste, sand-like granite slag waste, and sand-like glass slag waste.

[0060] S2: Mix clay slurry with sandy brick slag waste, sandy granite slag waste, sandy glass slag waste, and aluminum ash. After the mixture is evenly mixed, press it into shape using a pressing device to obtain the initial thick brick blank.

[0061] S3: The initial thick brick blank is dried, coated with slip, inkjet-printed with granite patterns, and glazed. Finally, it is sintered in a furnace at 750℃-850℃ for 5 minutes, then at 900℃-1000℃ for 10 minutes, and finally at 1150℃-1200℃ for 65 minutes. After cooling, the resulting environmentally friendly, high-strength, imitation granite ultra-thick brick is obtained. Figure 1 As shown.

[0062] Example 2

[0063] An environmentally friendly, high-strength, granite-like ultra-thick brick comprises the following components in parts by weight:

[0064] 10 parts clay, 10 parts aluminum ash, 2 parts sandy brick slag waste, 3 parts sandy granite slag waste, and 5 parts sandy glass slag waste.

[0065] The average particle size of the sandy brick slag waste is 0.4 mm; the average particle size of the sandy granite slag waste is 0.5 mm; and the average particle size of the sandy glass slag waste is 0.8 mm.

[0066] The main chemical composition of clay includes the following components by weight percentage:

[0067] The composition is as follows: SiO2 50%, Al2O3 42%, Fe2O3 0.1%, CaO 0.2%, MgO 0.2%, K2O 0.01%, Na2O 0.01%, TiO2 0.01%, with the remainder being water of crystallization.

[0068] The main chemical composition of aluminum ash includes the following components by weight percentage:

[0069] Al2O380%, SiO212%, MgO 8%.

[0070] The main chemical composition of sandy brick slag waste includes the following components by weight percentage:

[0071] CaSiO389.7%, SiO25%, Al2O35%, Fe2O30.2%, CaO 0.1%.

[0072] The sandy granite slag waste comprises the following components by weight percentage:

[0073] SiO2 75%, mica 8%, feldspar 17%.

[0074] The main chemical composition of sandy glass slag waste includes the following components by weight percentage:

[0075] SiO275%, Na2SiO310%, CaSiO35%, Al2O36%, MnO 4%.

[0076] It is prepared using the following steps:

[0077] S1: Clay is wet-milled into a slurry to obtain clay slurry; brick slag waste, granite slag waste, and glass slag waste are respectively processed into sand-like materials by sand-making equipment to obtain sand-like brick slag waste, sand-like granite slag waste, and sand-like glass slag waste.

[0078] S2: Mix clay slurry with sandy brick slag waste, sandy granite slag waste, sandy glass slag waste, and aluminum ash. After the mixture is evenly mixed, press it into shape using a pressing device to obtain the initial thick brick blank.

[0079] S3: The initial thick brick blank is dried, sprayed with slip, inkjet-sprayed to create granite patterns, and sprayed with colored dry granules. Finally, it is sintered in a furnace at 750℃-850℃ for 5 minutes, then at 900℃-1000℃ for 10 minutes, and finally at 1150℃-1200℃ for 65 minutes. After cooling and polishing, an environmentally friendly, high-strength, imitation granite ultra-thick brick is obtained. Figure 2 and Figure 3 As shown.

[0080] Example 3

[0081] An environmentally friendly, high-strength, granite-like ultra-thick brick comprises the following components in parts by weight:

[0082] 10 parts clay, 30 parts aluminum ash, 5 parts sandy brick slag waste, 10 parts sandy granite slag waste, and 5 parts sandy glass slag waste.

[0083] The average particle size of the sandy brick slag waste is 0.4 mm; the average particle size of the sandy granite slag waste is 0.5 mm; and the average particle size of the sandy glass slag waste is 0.8 mm.

[0084] The main chemical composition of clay includes the following components by weight percentage:

[0085] The composition is as follows: SiO2 50%, Al2O3 42%, Fe2O3 0.1%, CaO 0.2%, MgO 0.2%, K2O 0.01%, Na2O 0.01%, TiO2 0.01%, with the remainder being water of crystallization.

[0086] The main chemical composition of aluminum ash includes the following components by weight percentage:

[0087] Al2O380%, SiO212%, MgO 8%.

[0088] The main chemical composition of sandy brick slag waste includes the following components by weight percentage:

[0089] CaSiO389.7%, SiO25%, Al2O35%, Fe2O30.2%, CaO 0.1%.

[0090] The sandy granite slag waste comprises the following components by weight percentage:

[0091] SiO2 75%, mica 8%, feldspar 17%.

[0092] The main chemical composition of sandy glass slag waste includes the following components by weight percentage:

[0093] SiO275%, Na2SiO310%, CaSiO35%, Al2O36%, MnO 4%.

[0094] It is prepared using the following steps:

[0095] S1: Clay is wet-milled into a slurry to obtain clay slurry; brick slag waste, granite slag waste, and glass slag waste are respectively processed into sand-like materials by sand-making equipment to obtain sand-like brick slag waste, sand-like granite slag waste, and sand-like glass slag waste.

[0096] S2: Mix clay slurry with sandy brick slag waste, sandy granite slag waste, sandy glass slag waste, and aluminum ash. After the mixture is evenly mixed, press it into shape using a pressing device to obtain the initial thick brick blank.

[0097] S3: The initial thick brick blank is dried, sprayed with slip, inkjet-sprayed to create granite patterns, and sprayed with colored dry granules. Finally, it is placed in a firing furnace for sintering at 750℃-850℃ for 5 minutes, then at 900℃-1000℃ for 10 minutes, and finally at 1150℃-1200℃ for 65 minutes. After cooling and polishing, the environmentally friendly, high-strength imitation granite ultra-thick brick is obtained.

[0098] Example 4

[0099] An environmentally friendly, high-strength, granite-like ultra-thick brick comprises the following components in parts by weight:

[0100] 20 parts clay, 50 parts aluminum ash, 15 parts sandy brick slag waste, 3 parts sandy granite slag waste, and 3 parts sandy glass slag waste.

[0101] The average particle size of the sandy brick slag waste is 0.4 mm; the average particle size of the sandy granite slag waste is 0.5 mm; and the average particle size of the sandy glass slag waste is 0.8 mm.

[0102] The main chemical composition of clay includes the following components by weight percentage:

[0103] The composition is as follows: SiO2 50%, Al2O3 42%, Fe2O3 0.1%, CaO 0.2%, MgO 0.2%, K2O 0.01%, Na2O 0.01%, TiO2 0.01%, with the remainder being water of crystallization.

[0104] The main chemical composition of aluminum ash includes the following components by weight percentage:

[0105] Al2O380%, SiO211.8%, MgO 8%, ZnO 0.1%, CaO 0.1%.

[0106] The main chemical composition of sandy brick slag waste includes the following components by weight percentage:

[0107] CaSiO389.7%, SiO25%, Al2O35%, Fe2O30.2%, CaO 0.1%.

[0108] The sandy granite slag waste comprises the following components by weight percentage:

[0109] SiO2 75%, mica 8%, feldspar 17%.

[0110] The main chemical composition of sandy glass slag waste includes the following components by weight percentage:

[0111] SiO275%, Na2SiO310%, CaSiO35%, Al2O36%, MnO 4%.

[0112] It is prepared using the following steps:

[0113] S1: Clay is wet-milled into a slurry to obtain clay slurry; brick slag waste, granite slag waste, and glass slag waste are respectively processed into sand-like materials by sand-making equipment to obtain sand-like brick slag waste, sand-like granite slag waste, and sand-like glass slag waste.

[0114] S2: Mix clay slurry with sandy brick slag waste, sandy granite slag waste, sandy glass slag waste, and aluminum ash. After the mixture is evenly mixed, press it into shape using a pressing device to obtain the initial thick brick blank.

[0115] S3: The initial thick brick blank is dried, sprayed with slip, inkjet-sprayed to create granite patterns, and sprayed with colored dry granules. Finally, it is sintered in a furnace at 750℃-850℃ for 5 minutes, then at 900℃-1000℃ for 10 minutes, and finally at 1150℃-1200℃ for 65 minutes. After cooling and polishing, an environmentally friendly, high-strength, imitation granite ultra-thick brick is obtained. Figure 3 and Figure 4 As shown.

[0116] Example 5

[0117] An environmentally friendly, high-strength, granite-like ultra-thick brick comprises the following components in parts by weight:

[0118] 20 parts clay, 60 parts aluminum ash, 20 parts sandy brick slag waste, 3 parts sandy granite slag waste, and 3 parts sandy glass slag waste.

[0119] The average particle size of the sandy brick slag waste is 0.4 mm; the average particle size of the sandy granite slag waste is 0.5 mm; and the average particle size of the sandy glass slag waste is 0.8 mm.

[0120] The main chemical composition of clay includes the following components by weight percentage:

[0121] The composition is as follows: SiO2 50%, Al2O3 42%, Fe2O3 0.1%, CaO 0.2%, MgO 0.2%, K2O 0.01%, Na2O 0.01%, TiO2 0.01%, with the remainder being water of crystallization.

[0122] The main chemical composition of aluminum ash includes the following components by weight percentage:

[0123] Al2O380%, SiO211.8%, MgO 8%, ZnO 0.1%, CaO 0.1%.

[0124] The main chemical composition of sandy brick slag waste includes the following components by weight percentage:

[0125] CaSiO389.5%, SiO25%, Al2O35%, Fe2O30.2%, CaO 0.1%, Cr2O30.1%, ZrO20.1%.

[0126] The sandy granite slag waste comprises the following components by weight percentage:

[0127] SiO2 75%, mica 8%, feldspar 17%.

[0128] The main chemical composition of sandy glass slag waste includes the following components by weight percentage:

[0129] SiO275%, Na2SiO310%, CaSiO35%, Al2O36%, MnO 4%.

[0130] It is prepared using the following steps:

[0131] S1: Clay is wet-milled into a slurry to obtain clay slurry; brick slag waste, granite slag waste, and glass slag waste are respectively processed into sand-like materials by sand-making equipment to obtain sand-like brick slag waste, sand-like granite slag waste, and sand-like glass slag waste.

[0132] S2: Mix clay slurry with sandy brick slag waste, sandy granite slag waste, sandy glass slag waste, and aluminum ash. After the mixture is evenly mixed, press it into shape using a pressing device to obtain the initial thick brick blank.

[0133] S3: The initial thick brick blank is dried, sprayed with slip, inkjet-sprayed to create granite patterns, and sprayed with colored dry granules. Finally, it is placed in a firing furnace for sintering at 750℃-850℃ for 5 minutes, then at 900℃-1000℃ for 10 minutes, and finally at 1150℃-1200℃ for 65 minutes. After cooling and polishing, the environmentally friendly, high-strength imitation granite ultra-thick brick is obtained.

[0134] Example 6

[0135] An environmentally friendly, high-strength, granite-like ultra-thick brick comprises the following components in parts by weight:

[0136] 30 parts clay, 40 parts aluminum ash, 20 parts sandy brick slag waste, 20 parts sandy granite slag waste, and 15 parts sandy glass slag waste.

[0137] The average particle size of the sandy brick slag waste is 0.4 mm; the average particle size of the sandy granite slag waste is 0.5 mm; and the average particle size of the sandy glass slag waste is 0.8 mm.

[0138] The main chemical composition of clay includes the following components by weight percentage:

[0139] The composition is as follows: SiO2 50%, Al2O3 42%, Fe2O3 0.1%, CaO 0.2%, MgO 0.2%, K2O 0.01%, Na2O 0.01%, TiO2 0.01%, with the remainder being water of crystallization.

[0140] The main chemical composition of aluminum ash includes the following components by weight percentage:

[0141] Al2O380%, SiO211.8%, MgO 8%, ZnO 0.1%, CaO 0.1%.

[0142] The main chemical composition of sandy brick slag waste includes the following components by weight percentage:

[0143] CaSiO389.5%, SiO25%, Al2O35%, Fe2O30.2%, CaO 0.1%, Cr2O30.1%, ZrO20.1%.

[0144] The sandy granite slag waste comprises the following components by weight percentage:

[0145] SiO2 75%, mica 8%, feldspar 17%.

[0146] The main chemical composition of sandy glass slag waste includes the following components by weight percentage:

[0147] SiO275%, Na2SiO310%, CaSiO35%, Al2O36%, MnO 4%.

[0148] It is prepared using the following steps:

[0149] S1: Clay is wet-milled into a slurry to obtain clay slurry; brick slag waste, granite slag waste, and glass slag waste are respectively processed into sand-like materials by sand-making equipment to obtain sand-like brick slag waste, sand-like granite slag waste, and sand-like glass slag waste.

[0150] S2: Mix clay slurry with sandy brick slag waste, sandy granite slag waste, sandy glass slag waste, and aluminum ash. After the mixture is evenly mixed, press it into shape using a pressing device to obtain the initial thick brick blank.

[0151] S3: The initial thick brick blank is dried, sprayed with slip, inkjet-sprayed to create granite patterns, and sprayed with colored dry granules. Finally, it is placed in a firing furnace for sintering at 750℃-850℃ for 5 minutes, then at 900℃-1000℃ for 10 minutes, and finally at 1150℃-1200℃ for 65 minutes. After cooling and polishing, the environmentally friendly, high-strength imitation granite ultra-thick brick is obtained.

[0152] Example 7

[0153] An environmentally friendly, high-strength, granite-like ultra-thick brick comprises the following components in parts by weight:

[0154] 15 parts clay, 55 parts aluminum ash, 8 parts sandy brick slag waste, 3 parts sandy granite slag waste, 3 parts sandy glass slag waste; 2 parts aluminum dihydrogen phosphate; 2 parts magnesium oxide; 2 parts ceramic particles.

[0155] The average particle size of the sandy brick slag waste is 0.4 mm; the average particle size of the sandy granite slag waste is 0.5 mm; and the average particle size of the sandy glass slag waste is 0.8 mm.

[0156] The main chemical composition of clay includes the following components by weight percentage:

[0157] The composition is as follows: SiO2 50%, Al2O3 42%, Fe2O3 0.1%, CaO 0.2%, MgO 0.2%, K2O 0.01%, Na2O 0.01%, TiO2 0.01%, with the remainder being water of crystallization.

[0158] The main chemical composition of aluminum ash includes the following components by weight percentage:

[0159] Al2O380%, SiO211.8%, MgO 8%, ZnO 0.1%, CaO 0.1%.

[0160] The main chemical composition of sandy brick slag waste includes the following components by weight percentage:

[0161] CaSiO389.5%, SiO25%, Al2O35%, Fe2O30.2%, CaO 0.1%, Cr2O30.1%, ZrO20.1%.

[0162] The sandy granite slag waste comprises the following components by weight percentage:

[0163] SiO2 75%, mica 8%, feldspar 17%.

[0164] The main chemical composition of sandy glass slag waste includes the following components by weight percentage:

[0165] SiO275%, Na2SiO310%, CaSiO35%, Al2O36%, MnO 4%.

[0166] It is prepared using the following steps:

[0167] S1: Clay is wet-milled into a slurry to obtain clay slurry; brick slag waste, granite slag waste, and glass slag waste are respectively processed into sand-like materials by sand-making equipment to obtain sand-like brick slag waste, sand-like granite slag waste, and sand-like glass slag waste.

[0168] S2: Clay slurry is mixed with sandy brick slag waste, sandy granite slag waste, sandy glass slag waste, aluminum ash, aluminum dihydrogen phosphate, magnesium oxide, and ceramic particles. After the mixture is evenly mixed, it is pressed into shape by pressing equipment to obtain the initial thick brick blank.

[0169] S3: The initial thick brick blank is dried, sprayed with slip, inkjet-sprayed to create granite patterns, and sprayed with colored dry granules. Finally, it is placed in a firing furnace for sintering at 750℃-850℃ for 5 minutes, then at 900℃-1000℃ for 10 minutes, and finally at 1150℃-1200℃ for 65 minutes. After cooling and polishing, the environmentally friendly, high-strength imitation granite ultra-thick brick is obtained.

[0170] Comparative Example 1

[0171] The only difference between Comparative Example 1 and Example 1 is that no sandy brick slag waste and sandy granite slag waste were added, and the amount of sandy glass slag waste was increased from 5 parts to 9 parts. Otherwise, it is the same as Example 1.

[0172] Comparative Example 2

[0173] The only difference between Comparative Example 2 and Example 1 is that the aluminum ash was reduced from 5 parts to 4 parts, and everything else was the same as Example 1.

[0174] Comparative Example 3

[0175] The only difference between Comparative Example 3 and Example 1 is that the aluminum ash was increased from 5 parts to 65 parts, and everything else was the same as Example 1.

[0176] Comparative Example 4

[0177] The only difference between Comparative Example 4 and Example 1 is that powdered brick slag waste is used instead of sandy brick slag waste, powdered granite slag waste is used instead of sandy granite slag waste, and powdered glass slag waste is used instead of sandy glass slag waste. Everything else is the same as Example 1.

[0178] Performance testing

[0179] 1. The comparative and example samples will be tested for water absorption and mechanical properties, and their internal and surface appearance will be observed. Water absorption will be tested according to GB / T 4100-2015, compressive strength of finished products will be tested according to GT / B 4740-1999, breaking strength will be tested according to GB / T3810.4-2006, permeability coefficient will be tested according to GB 50204-2015, abrasion resistance will be tested according to GB / T 17671-1999, frost resistance will be tested according to GB / T3810.12-2016, and thermal shock resistance will be tested according to GB / T3810.9-2016.

[0180] 2. The test results are shown in Table 1 below.

[0181] Table 1

[0182]

[0183]

[0184]

[0185] The above embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of protection of the present invention. Any non-substantial changes and substitutions made by those skilled in the art based on the present invention shall fall within the scope of protection claimed by the present invention.

Claims

1. An environment-friendly high-strength granite-imitated super-thick brick, characterized in that, Comprise the following components by weight: Clay 5-30 parts, aluminum ash 5-60 parts, sand-like brick slag waste 1-20 parts, sand-like granite slag waste 1-20 parts, sand-like glass slag waste 1-20 parts; The thickness of the environmentally friendly high-strength imitation granite super-thick brick is 30-60 mm, and the water absorption rate is 2-8%; The main chemical composition of the clay includes the following components by weight percentage: SiO2 40-50%, Al2O3 40-45%, Fe2O3 0.1-0.5%, CaO 0.1-0.5%, MgO 0.1-0.5%, K2O 0.01-0.1%, Na2O 0.01-0.1%, TiO2 0.01-0.1%, and the rest is crystal water; The main chemical composition of the aluminum ash includes the following components by weight percentage: Al2O3 70-85%, SiO2 12-20%, MgO 4.5-10%, MnO 0-0.1%, ZnO 0-0.1%, CaO 0-0.1%; The main chemical composition of the sand-like brick slag waste includes the following components by weight percentage: CaSiO3 80-90%, SiO2 5-10%, Al2O3 5-10%, Fe2O3 0.1-0.5%, CaO 0.1-0.5%, Cr2O3 0-0.1%, ZrO2 0-0.1%; The sand-like granite slag waste includes the following components by weight percentage: SiO2 65-85%, mica 5-15%, feldspar 2-20%; The main chemical composition of the sand-like glass slag waste includes the following components by weight percentage: SiO2 60-75%, Na2SiO3 10-15%, CaSiO3 5-15%, Al2O3 3-6%, MnO 1-4%; The preparation method of the environmentally friendly high-strength imitation granite super-thick brick includes the following preparation steps: S1: Clay is ground into slurry by wet ball milling to obtain clay slurry; brick slag waste, granite slag waste, and glass slag waste are respectively ground into corresponding sand-like shapes by sand-making equipment to obtain sand-like brick slag waste, sand-like granite slag waste, and sand-like glass slag waste; S2: The clay slurry, sand-like brick slag waste, sand-like granite slag waste, sand-like glass slag waste, and aluminum ash are mixed uniformly, and then pressed into shape by pressing equipment to obtain an initial thick brick blank; S3: The initial thick brick blank is dried, sprayed with decorative clay, sprayed with ink to decorate the pattern of granite, sprayed with colored dry particles or glaze, and finally sintered in a sintering furnace to obtain the final product. The sintering curve is as follows: first, 750-850°C for 5-10 minutes, then 900-1000°C for 10-20 minutes, and finally, 1150-1200°C for 50-65 minutes, and then cooled.

2. The eco-friendly high strength granite look ultra thick tile as claimed in claim 1, wherein, The environment-friendly high-strength granite-like super-thick brick comprises the following components by weight: 20-30 parts of clay, 30-50 parts of aluminum ash, 3-10 parts of sand-like brick slag waste, 2-6 parts of sand-like granite stone slag waste, and 5-15 parts of sand-like glass slag waste.

3. The eco-friendly high strength granite look ultra thick tile as claimed in claim 1 wherein, The mass ratio of Al2O3, SiO2 and MgO in the aluminum ash is 80:(12-13):(5-8).

4. The eco-friendly high strength granite look ultra thick tile as claimed in claim 1 wherein, The average particle size of the sand-like brick slag waste is 0.1-1 mm, the average particle size of the sand-like granite stone slag waste is 0.1-1 mm, and the average particle size of the sand-like glass slag waste is 0.1-1 mm.

5. A process for the production of an eco-friendly high strength granite lookalike super thick tile as claimed in any of the claims 1 to 4, wherein, The preparation steps include the following steps: S1: clay is wet-milled into slurry to obtain clay slurry; brick slag waste, granite stone slag waste and glass slag waste are respectively made into corresponding sand-like shapes by sand-making equipment to obtain sand-like brick slag waste, sand-like granite stone slag waste and sand-like glass slag waste; S2: the clay slurry, sand-like brick slag waste, sand-like granite stone slag waste, sand-like glass slag waste and aluminum ash are mixed, and then uniformly mixed and pressed by pressing equipment to obtain an initial thick brick blank; S3: the initial thick brick blank is dried, sprayed with cosmetic clay, sprayed with ink to decorate the pattern of granite, sprayed with colored dry particles or sprayed with glaze, and finally sintered in a sintering furnace to obtain the environment-friendly high-strength granite-like super-thick brick, wherein the sintering curve is as follows: first sintering at 750-850 DEG C for 5-10 min, then sintering at 900-1000 DEG C for 10-20 min, and finally sintering at 1150-1200 DEG C for 50-65 min, and then cooling.

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