An energy-saving curing matrix production process and device

Abstract

The application discloses an energy-saving curing matrix production process and device, and relates to the field of curing matrix production.The energy-saving curing matrix comprises fiber culture soil and a framework;the framework comprises a framework body and a plurality of support columns arranged on the framework body;the framework body is in a net structure and is arranged at the bottom of the curing matrix;the support columns penetrate through the thickness of the fiber culture soil layer;the bottom of the framework body is provided with a plurality of protruding parts which are matched with the positions of the support columns and are beneficial to air convection between upper and lower layers during stacking;and a filter layer is arranged between the framework body and the fiber culture soil layer.The production process of the energy-saving curing matrix does not need drying treatment, has the characteristics of light weight, excellent drainage performance, simple construction, facilitation to plant growth and green environmental protection, and becomes an urgent need in the three-dimensional greening industry.

Description

[0001] This application is a divisional application of the invention patent application filed on July 27, 2022, with application number 202210887901.1 and invention titled "A Production Process and Apparatus for an Energy-Saving Curing Substrate". Technical Field

[0002] This invention relates to the field of greening, and specifically to an energy-saving process and apparatus for producing solidified substrates. Background Technology

[0003] In recent years, to promote greening and protect the environment, greening has begun on rooftops, artificial slopes, road medians, and high-rise building walls. A common method for this is to first place potting soil in a plastic tray or non-woven bag, then add plant seeds. After the plants have grown, they are transferred along with the tray or bag to the rooftop or artificial slope. However, this method has drawbacks. The heavy substrate puts significant stress on the base, creating safety hazards. Furthermore, it leads to soil erosion, poor drainage, soil compaction during heavy rains, and dust storms during sunny weather, all of which are detrimental to plant growth and environmental protection.

[0004] In existing technologies, some researchers have proposed using a solidified matrix (whose raw materials include soil, plant fibers, nutrients, and binders). However, because the preparation process requires steam heating, the solidified matrix has a high moisture content. Therefore, traditional solidified matrices require drying, which is costly, time-consuming, and unsuitable for large-scale production. Furthermore, due to insufficient hardness, the solidified matrix is ​​prone to collapse and deformation during stacking, reducing space utilization and hindering mechanized processing. During the demolding process of the solidified matrix, either a flipping mold or an ejection mold is commonly used. Flipping molds require flipping the mold, which is lightweight and has low precision. Ejection molds require a designed ejection mechanism, which has a complex mold structure and poor reliability.

[0005] Because the preparation process requires steam heating, the thickness of the solidified matrix cannot be too thick. In the existing process, the fiber soil cannot be solidified beyond the 5cm limit. The thickness of a single solidified matrix limits its application range and is not conducive to the large-scale promotion and application of solidified matrix.

[0006] Therefore, it is necessary to develop an energy-saving solidified matrix production process and equipment to fundamentally solve the above problems. Summary of the Invention

[0007] To address the shortcomings of existing technologies, the present invention aims to provide an energy-saving solidified substrate production process and apparatus. The solidified substrate does not require drying during production and is characterized by its light weight, excellent drainage performance, simple construction, promotion of plant growth, and environmental friendliness, making it urgently needed in the vertical greening industry.

[0008] To achieve the above objectives, the present invention provides the following technical solution: This invention provides an energy-saving solidification matrix, which comprises fiber culture soil and a framework; The skeleton includes a frame body and multiple support columns disposed on the frame body. The frame body is a mesh structure and is disposed at the bottom of the solidified substrate. The support columns penetrate the thickness of the fiber culture soil layer. The bottom of the frame body is provided with multiple protrusions, which are adapted to the position of the support column. When stacking in the forward direction, the upper and lower layers of solidified matrix are seamlessly bonded, and when stacking in the reverse direction, a convection gap is formed between the upper and lower layers of solidified matrix. A filter layer is provided between the frame body and the fiber culture soil layer. By setting up the filter layer, it is possible to prevent fiber soil debris from clogging the drainage holes and drainage pipes.

[0009] The diameter of the protrusion is smaller than the inner diameter of the support column. The support column is a hollow structure. When stacking in the forward direction, the protrusion of the upper layer of curing matrix is ​​just embedded in the support column of the lower layer of curing matrix, so as to achieve seamless bonding between the upper and lower layers of curing matrix. When stacking in the reverse direction, the protrusions of the upper and lower layers of curing matrix come into contact with each other, forming a convection gap between the upper and lower layers of curing matrix, which is conducive to air convection.

[0010] The filter layer is made of non-woven geotextile.

[0011] The skeleton is manufactured using an injection molding process, and the material of the skeleton is one or more of metal, resin, and plastic.

[0012] The support columns consist of four pillars, and the upper surface of the cured substrate is provided with a barbed structure, which is fixedly connected to the top of the four support columns. By providing the barbed structure, the frame can be quickly lifted to remove the cured substrate product from the mold.

[0013] The skeleton has a connecting structure between adjacent units to increase stability during assembly.

[0014] The frame body has snap-fit ​​connectors on its sides, and adjacent frame bodies have matching grooves, forming a snap-fit ​​connection structure. This facilitates the assembly of multiple cured substrates together, enabling overall roof installation.

[0015] The raw materials of the fiber culture soil include base soil, plant fiber, nutrient components and binder; the fiber culture soil of the present invention is made using existing technology or obtained through commercial means, and the fiber culture soil needs to be adjusted according to the characteristics of the plant being cultured.

[0016] This invention also provides a production process for the energy-saving curing substrate, comprising the following steps: (1) The skeleton was prepared using injection molding process; (2) Mix the raw materials of the fiber culture soil evenly to obtain the fiber culture soil; (3) Place the skeleton at the bottom of the mold, keep the support column facing upward, lay the filter layer on the upper surface of the frame body, add fiber culture soil, fill it and scrape it flat, and then perform mold closing and hot pressing treatment in sequence to solidify the fiber culture soil, filter layer and skeleton. The bottom of the mold body is provided with multiple grooves, which are adapted to the protrusions on the bottom of the frame body; (4) Finally, demolding is performed to obtain the cured matrix.

[0017] The mold's pressing block is equipped with a high-temperature steam heating system.

[0018] The mold base plate has multiple water outlet holes evenly distributed.

[0019] An energy-saving production apparatus for a curing matrix, wherein the mold includes a mold body and a pressing block, the top of the mold body being open; the pressing block is located directly above the mold body and is connected to a pressure mechanism, under the action of the pressure mechanism, the pressing block moves up and down along the inner wall of the mold body; The bottom of the mold body is provided with multiple grooves, which are adapted to the protrusions at the bottom of the frame body; The base plate of the mold body has multiple water outlet holes evenly distributed; The press block is equipped with a high-temperature steam heating system, and multiple steam holes are evenly distributed on the press block panel.

[0020] Compared with the prior art, the beneficial technical effects of the present invention are as follows: (1) The energy-saving solidified substrate provided by the present invention, by setting up protrusions, support columns and connecting structures, achieves seamless bonding of the upper and lower solidified substrates when stacking in the forward direction, and can obtain an ultra-thick solidified substrate, which solves the problem that the traditional fiber soil layer cannot break through the 5cm limit. The solidified substrate can be spliced ​​into flower boxes and Rubik's Cubes, realizing the solidification of the whole substrate. In the extremely cold northern regions, the ultra-thick solidified substrate can enhance the cold resistance of plants and broaden the application range.

[0021] (2) The energy-saving solidified substrate provided by the present invention forms a convection gap between the upper and lower solidified substrates when stacked in reverse, which helps the moisture in the fiber soil to evaporate and dry, without the need for drying treatment; by setting the protrusion, it is equivalent to setting a water storage and drainage board on the bottom surface of the solidified substrate during the paving, which is conducive to the drainage of water from the solidified substrate and prevents the solidified substrate from being too heavy due to excessive water storage, which would cause the roof to be overloaded.

[0022] (3) The energy-saving solidification matrix provided by the present invention combines fiber culture soil and skeleton by bonding and winding. The weight of stacking is borne by the support column of the skeleton, so the fiber culture soil will not be crushed. It is not easy to collapse and deform during stacking, which is conducive to mechanized operation.

[0023] (4) The energy-saving solidified substrate provided by the present invention combines the functions of "fiber soil layer + filter layer + drainage and water storage board", realizing the function of "three in one", and the paving operation is more effective and more convenient.

[0024] (5) The present invention provides a production process for an energy-saving solidified substrate. The skeleton structure is embedded in the solidified substrate, and the moisture content in the fiber soil is reduced by natural air drying. It can be directly picked up and stacked, which greatly reduces transportation costs. It not only saves drying energy consumption and oven costs, but also breaks through the production capacity bottleneck of drying, which has great economic significance.

[0025] (6) The present invention provides an energy-saving production device for curing matrix. Since the frame is provided with a mold removal structure, the frame can be lifted quickly to remove the curing matrix product from the mold, making mold removal more labor-saving and efficient. Compared with the flipping mold removal method, there is no need to flip the mold, the mold weight can be larger, the mold structure design is less restricted, the accuracy can be improved, and the mold reliability is improved. Compared with the ejection mold removal method, there is no need to design an ejection mechanism, the mold structure is simplified, and the reliability is higher. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the structure of the solidified matrix.

[0027] Figure 2 This is a side view of the cured substrate.

[0028] Figure 3 This is a structural diagram of the frame body.

[0029] Figure 4 This is a front view of the production equipment for energy-saving curing substrates.

[0030] Figure 5 This is a top view of the main body of the mold.

[0031] Figure 6 This is a top view of the briquette.

[0032] Figure 7 A schematic diagram of the structure for forward stacking of the solidified substrate.

[0033] Figure 8 A schematic diagram of a flower box formed by stacking and solidifying the substrate in the forward direction.

[0034] Figure 9 This is a schematic diagram of a structure for reverse stacking of a cured substrate.

[0035] In the diagram: 1-Fiber culture soil; 2-Skeleton; 201-Frame body; 202-Support column; 203-Protrusion; 3-Filter layer; 4-Connecting structure; 401-Snap connector; 402-Groove; 5-Mold body; 6-Pressure block; 7-Groove; 8-Water outlet; 9-Steam hole; 10-Hook structure. Detailed Implementation

[0036] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0037] The present invention will be further described below with reference to specific embodiments and accompanying drawings.

[0038] Example 1 like Figure 1-3 As shown, an energy-saving solidification substrate comprises fiber culture soil 1 and a skeleton 2; The skeleton 2 includes a frame body 201 and four support columns 202 set on the frame body. The frame body 201 is a mesh structure and is set at the bottom of the solidified substrate. The support columns 202 penetrate the thickness of the fiber culture soil layer. The bottom of the frame body 201 is provided with multiple protrusions 203, which are adapted to the positions of the support columns 202, which is conducive to the formation of air convection between the upper and lower layers during stacking. A filter layer 3 is provided between the frame body 201 and the fiber culture soil layer. The filter layer is made of non-woven geotextile, which can prevent fiber soil from falling off and clogging the drainage holes and drainage pipes.

[0039] The skeleton 2 is made by injection molding, and the material of the skeleton is ABS plastic.

[0040] There are four support columns 202. The upper surface of the solidified substrate is provided with a barb structure 10, which is fixedly connected to the top of the four support columns 202.

[0041] like Figure 4-6 As shown, an energy-saving curing matrix production device includes a mold body 5 and a pressing block 6. The top of the mold body is open. The pressing block is located directly above the mold body and is connected to a pressure mechanism. Under the action of the pressure mechanism, the pressing block moves up and down along the inner wall of the mold body. The bottom of the mold body 5 is provided with 4 grooves 7, which are adapted to the protrusions 203 at the bottom of the frame body; Multiple water outlet holes 8 are evenly distributed on the base plate of the mold body 5; The press block 6 is equipped with a high-temperature steam heating system, and multiple steam holes 9 are evenly distributed on the press block panel.

[0042] A production process for an energy-saving curing substrate, characterized by comprising the following steps: (1) The skeleton was prepared using injection molding process; (2) Mix the raw materials of the fiber culture soil evenly to obtain the fiber culture soil; The raw materials of the fiber culture soil include base soil (25wt%), plant fiber (30wt%), nutrient components (35wt%) and binder (10wt%). The nutrient components are perlite 28wt%, peat soil 2wt%, plant fertilizer 5wt%, and the binder is thermoplastic polymer. (3) Place the skeleton at the bottom of the mold, keep the support column facing upward, lay the filter layer (non-woven geotextile) on the upper surface of the frame body, add fiber culture soil, fill it and scrape it flat, and then perform mold closing and hot pressing treatment in sequence. The temperature of the hot pressing treatment is 120℃ and the hot pressing time is 30min; so that the fiber culture soil, filter layer and skeleton are solidified and formed. (4) Lift the barb structure 10 on the skeleton to remove the solidified matrix product from the mold, thus obtaining the... Solidified matrix.

[0043] By embedding a skeleton structure within the solidified matrix and utilizing natural air drying to reduce the moisture content in the fiber soil, it can be directly picked up and stacked, greatly reducing transportation costs and saving drying costs of 20 yuan per square meter. This not only eliminates the need for drying energy consumption and oven costs but also breaks through the production capacity bottleneck of drying, which has significant economic implications.

[0044] The physical properties of the energy-saving curing matrix obtained in Example 1 are shown in Table 1.

[0045] Table 1 Physical properties of the cured matrix Example 2 The solidified substrate product provided by this invention is specifically applied to rooftop greening with a slope of less than 30 degrees. In rooftop greening, the framework is located at the bottom of the solidified substrate, the fibrous culture soil is on the surface, and turf is planted on the surface.

[0046] The frame has a connection structure 4 between adjacent units to increase the stability of the solidified matrix when splicing on the roof; the side of the frame body has a snap joint 401, and the adjacent frame body has a groove 402 that matches it, forming a snap connection structure, which makes it easy to install on the roof to form a stable whole.

[0047] A filter layer 3 is provided between the frame body 201 and the fiber-grown soil layer. The filter layer is made of non-woven geotextile to prevent fiber soil debris from clogging the drainage holes and drainage pipes. A protrusion is provided at the bottom of the frame body to serve as a water storage and drainage board during installation. This helps to drain accumulated water from the solidified substrate and prevents the solidified substrate from becoming too heavy and overloading the roof.

[0048] Example 3 The curing matrix product provided by this invention, such as Figure 7 As shown, during forward stacking, the protrusions of the upper layer of cured substrate are precisely embedded into the support columns of the lower layer of cured substrate, achieving seamless bonding between the two layers. Laterally adjacent cured substrates are connected by structures on the frame to form a flower box, as shown. Figure 8 As shown, holes can be drilled directly into the fibrous soil surface, and then plants can be planted.

[0049] like Figure 9 As shown, during reverse stacking, the protrusions of the upper and lower solidified substrates come into contact with each other, forming a convection gap between the upper and lower solidified substrates. This helps the moisture in the fiber soil to evaporate and dry, eliminating the need for additional drying treatment.

[0050] The above description is merely a preferred embodiment of the present invention, and the scope of protection of the present invention is not limited to the above embodiments. For those skilled in the art, improvements and modifications obtained without departing from the inventive concept should also be considered within the scope of protection of the present invention.

Claims

1. A solidified matrix, characterized in that, The solidified substrate comprises fiber culture soil and a framework; the framework includes a frame body and multiple support columns disposed on the frame body. The frame body has a mesh structure and is located at the bottom of the solidified substrate; the support columns penetrate the thickness of the fiber culture soil layer; the bottom of the frame body has multiple protrusions, the protrusions being adapted to the positions of the support columns, achieving seamless adhesion between the upper and lower layers of solidified substrate when stacked in the forward direction, and forming a convection gap between the upper and lower layers of solidified substrate when stacked in the reverse direction; the diameter of the protrusions is smaller than the inner diameter of the support columns, and the support columns are hollow structures; when stacked in the forward direction, the protrusions of the upper layer of solidified substrate are precisely embedded in the support columns of the lower layer of solidified substrate, achieving seamless adhesion between the upper and lower layers of solidified substrate; when stacked in the reverse direction, the protrusions of the upper and lower layers of solidified substrate contact each other, forming a convection gap between the upper and lower layers of solidified substrate; the surface of the fiber culture soil is drilled with holes for planting plants, or the surface of the fiber culture soil is planted with turf.

2. The cured matrix according to claim 1, characterized in that, The solidified matrix has an embedded skeleton structure.

3. The curing matrix according to any one of claims 1-2, characterized in that, A filter layer is provided between the frame body and the fiber culture soil layer.

4. The curing matrix according to claim 3, characterized in that, The filter layer is made of non-woven geotextile.

5. The cured matrix according to claim 3, characterized in that, The raw materials of the fiber culture soil include base soil, plant fiber, nutrient components and binder.

6. The cured matrix according to claim 5, characterized in that, The nutrient components are perlite, peat moss, and plant fertilizer, and the binder is a thermoplastic polymer.

7. The curing matrix according to any one of claims 1-2, characterized in that, The skeleton is made of one or more of the following materials: metal, resin, and plastic.

8. The curing matrix according to claim 7, characterized in that, The skeleton is manufactured using an injection molding process.

9. The curing matrix according to any one of claims 1-2, characterized in that, The support columns consist of four pillars, and the upper surface of the solidified substrate is provided with a barb structure, which is fixedly connected to the top of the four support columns.

10. The cured matrix according to any one of claims 1-2, characterized in that, The skeleton has a connection structure between adjacent units.

11. The cured matrix according to claim 10, characterized in that, The side of the frame body is provided with a fastener, and the adjacent frame body is provided with a matching groove to form a snap-fit ​​connection structure.

12. The cured matrix according to claim 10, characterized in that, The horizontally adjacent solidified substrates on the left and right sides form a flower box through the connecting structure on the skeleton.

13. The production process of the solidified matrix as described in any one of claims 1-12, characterized in that, Includes the following steps: (1) Place the skeleton at the bottom of the mold, keep the support column facing upward, add fiber culture soil to the upper surface of the frame body, fill it and scrape it flat, and then perform mold closing and hot pressing treatment in sequence to solidify the fiber culture soil and skeleton. The mold includes a mold body and a pressure block. The top of the mold body is open. The pressure block is located directly above the mold body and is connected to a pressure mechanism. Under the action of the pressure mechanism, the pressure block moves up and down along the inner wall of the mold body. The bottom of the mold body has multiple grooves that fit with the protrusions at the bottom of the frame body. The bottom plate of the mold body has multiple water outlet holes evenly distributed. The pressure block is equipped with a high-temperature steam heating system, and the pressure block panel has multiple steam holes evenly distributed. (2) Finally, demolding is performed to obtain the cured matrix.

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