Lightweight heat-insulating straw wall brick and production process thereof

Abstract

The application discloses light-weight heat-insulating straw wall brick in the technical field of building, which comprises waterproof layer, connecting layer, entity layer and several heat-insulating layers from outside to inside; the waterproof layer selects aerogel, the connecting layer selects foam ceramic, the entity layer selects straw, and the heat-insulating layer selects vacuum heat-insulating material. The production process of the light-weight heat-insulating straw wall brick comprises the following steps: step one, screening of crushed materials; step two, drying of raw materials; step three, feeding and stirring: adding binder and additives and stirring; step four, rolling into a mold: rolling to obtain straw homogeneous plate and wavy vacuum heat-insulating material; step five, surface finishing; step six, layer-by-layer installation; and step seven, 3D printing: 3D printing of the waterproof layer on the wall surface. The application improves the heat-insulating effect through the vacuum heat-insulating material, reduces the weight of the wall through the straw homogeneous plate made of straw, improves the heat-insulating effect of the wall and reduces the weight of the wall through the porous structure of the aerogel and the foam ceramic, and thus the light weight of the wall is highlighted.

Description

Technical Field

[0001] This invention belongs to the field of building technology, specifically lightweight heat-insulating straw wall bricks and their production process. Background Technology

[0002] Straw, when used as a building material, does not cause any pollution to the environment, nor does it produce any toxic or harmful substances. It can be said to be the most ideal building material, which can satisfy people's psychological need to return to nature and the concept of low-carbon, environmentally friendly and sustainable development.

[0003] Most existing walls are concrete walls, which are heavy and have relatively high thermal conductivity due to their main components being cement, sand, and aggregates, resulting in poor insulation. Therefore, it is necessary to propose lightweight insulating straw wall bricks and their production process. Summary of the Invention

[0004] To address the aforementioned problems, the present invention aims to propose a lightweight, heat-insulating straw wall brick and its production process. This process enhances the heat insulation effect through vacuum insulation materials; reduces the weight of the wall by using straw homogeneous boards made from straw; and improves the heat insulation effect of the wall and reduces its weight through the porous structure of aerogel and foam ceramics, thereby highlighting the lightweight characteristics of the wall.

[0005] To achieve the above objectives, the technical solution of the present invention is as follows: a lightweight heat-insulating straw wall brick, comprising, from the outside to the inside, a waterproof layer, a connecting layer, a solid layer, and several heat-insulating layers; the waterproof layer is fixedly connected to the connecting layer, the connecting layer is fixedly connected to the solid layer, the solid layer is fixedly connected to the adjacent heat-insulating layer, and adjacent heat-insulating layers are all fixedly connected to each other; the shape of the heat-insulating layers is wavy; the material of the waterproof layer is aerogel, the material of the connecting layer is foam ceramic, the material of the solid layer is straw, and the material of the heat-insulating layer is vacuum insulation material.

[0006] The above scheme achieves the following principles and beneficial effects:

[0007] Basic principles: Aerogel is hydrophobic and has excellent waterproofing capabilities; foam ceramics are characterized by high strength and low density, and their thermal insulation properties further enhance the thermal insulation performance of lightweight insulated straw wall bricks; straw homogeneous boards have good physical and mechanical properties and waterproofing performance; vacuum insulation materials, as a highly efficient thermal insulation material, have excellent thermal insulation, physical, and chemical properties, as well as good fire resistance. The design of vacuum insulation materials ensures the safety of lightweight insulated straw wall bricks.

[0008] Beneficial effects: 1. This invention improves the heat insulation effect through vacuum insulation materials; reduces the weight of the wall through straw homogeneous boards; and enhances the heat insulation effect of the wall through the porous structure of aerogel and foam ceramics, while reducing the weight of the wall, thus highlighting the lightweight characteristics of the wall.

[0009] 2. The waterproof layer design prevents water from entering the wall and causing it to become damp, thus increasing the wall's lifespan.

[0010] 3. The design of the connecting layer allows the walls to be connected to each other, which can greatly shorten the construction period and reduce labor costs during construction.

[0011] 4. The design of several wavy insulation layers further enhances the insulation effect of the wall, and the wavy design increases the contact surface between the insulation layers, making each insulation layer heat up evenly and thus better blocking heat.

[0012] 5. The design of using foam ceramic as a connecting layer makes full use of the high strength of foam ceramic. At the same time, because foam ceramic has a porous structure, it has a certain sound absorption effect, giving the lightweight heat-insulating straw wall bricks a certain sound absorption function.

[0013] 6. The design of placing aerogel on the outermost layer of lightweight insulated straw wall bricks makes full use of the hydrophobicity and fire resistance of aerogel, providing protection for the lightweight insulated straw wall bricks and increasing their service life.

[0014] Furthermore, the insulation layer has several through holes and channels, which are distributed alternately from top to bottom. The channels are filled with helium, the through holes are filled with argon, and several blocking components of different sizes are fixedly connected inside the through holes.

[0015] Beneficial effects: Argon gas possesses excellent thermal insulation properties. Its density and dynamic viscosity are both higher than air, while its thermal conductivity and specific heat capacity are lower. This allows argon gas to effectively slow down heat convection and conduction. Furthermore, the baffles inside the through-holes further impede the flow of argon gas, further slowing its movement and enhancing its thermal insulation performance. Helium gas, with a lower density than air, can provide a certain lifting force for lightweight insulated straw wall bricks, thus achieving the lightweight design of these bricks.

[0016] Furthermore, several connectors are fixedly connected to one side of the connecting layer, and several connecting holes corresponding to the connectors are opened on the side of the connecting layer away from the connectors, with the connecting holes communicating with the outside.

[0017] Beneficial effects: The design of connectors and connecting holes enables the modularization of lightweight heat-insulating straw wall bricks. Compared with traditional construction methods, modular construction greatly reduces the amount of on-site work and thus shortens the construction cycle.

[0018] Furthermore, the production process of lightweight heat-insulating straw wall bricks includes the following steps:

[0019] Step 1, Material Screening: Crush the selected straw and screen it.

[0020] Step 2, Raw material drying: The selected straw is dried.

[0021] Step 3, Adding and mixing: Add binders and additives to the dried straw raw material and mix thoroughly;

[0022] Step 4, Rolling into the mold: Pour the straw with added adhesive and additives into the homogenized plate mold and roll the straw to obtain a straw homogenized plate; Place a number of vacuum insulation materials into the insulation plate mold and press them into a wavy shape; Make a number of through holes and channels on the surface of the vacuum insulation materials, and fix a number of blocking parts inside each through hole.

[0023] Step 5, Surface finishing: Grind and finish the surface of the straw homogenization board;

[0024] Step 6, Layer-by-layer installation: Install foam ceramic onto the surface of the straw homogenous board, install vacuum insulation material into the straw homogenous board, and fill each through hole with argon gas for sealing, and fill each channel with helium gas for sealing.

[0025] Step 7, 3D printing: Use 3D printing technology to print a waterproof layer on the surface of foam ceramic.

[0026] Furthermore, in step one, when screening the straw, straw particles with a diameter greater than 10mm are removed, and straw particles of uniform size are retained.

[0027] Furthermore, in step two, when drying the straw, the moisture content of the straw is controlled between 6% and 8%.

[0028] Furthermore, in step three, a polymeric isocyanate adhesive is selected as the adhesive.

[0029] Furthermore, in step three, flame retardants are selected as additives.

[0030] Furthermore, in step five, when grinding the straw homogenized board, it is first coarsely ground and then finely ground.

[0031] Furthermore, in step six, when sealing the through holes and channels, aerogel is used as the sealing material.

[0032] Beneficial effects: 1. Selecting straw particles of uniform size can ensure a more uniform distribution of density and strength of the board, thereby improving the overall physical properties of the product. At the same time, the uniform size of the straw particles helps to reduce unevenness in the production process, such as voids and cracks, thereby improving the yield and quality stability of lightweight heat-insulating straw wall bricks.

[0033] 2. When drying straw, the moisture content of the straw is controlled between 6% and 8%, which makes the straw more stable during processing and less prone to deformation or expansion. This improves the dimensional stability and shape accuracy of the straw homogenization plate.

[0034] 3. Compared with traditional adhesives such as urea-formaldehyde resin, polymeric isocyanate adhesives generate fewer pollutants during production and use. At the same time, polymeric isocyanate adhesives have good flame retardancy and water resistance, which improves the safety of lightweight heat-insulating straw wall bricks.

[0035] 4. The addition of flame retardants further enhances the safety of lightweight heat-insulating straw wall bricks.

[0036] 5. The coarse-to-fine grinding process significantly improves the surface quality of the straw homogenized board, reducing the difficulty of subsequent processing.

[0037] 6. The through-hole design effectively reduces the weight of the lightweight heat-insulating straw wall bricks, thus highlighting the lightweight nature of the wall.

[0038] 7. The wavy design of vacuum insulation material increases the contact area between vacuum insulation materials, thereby increasing the heat conduction area. At the same time, the wavy design increases the relative thickness of the vacuum insulation material, thus enhancing the insulation effect. Attached Figure Description

[0039] Figure 1 This is an isometric schematic diagram of an embodiment of the present invention.

[0040] Figure 2 This is a top sectional view of the lightweight heat-insulating straw wall bricks in an embodiment of the present invention.

[0041] Figure 3 This is a side sectional view of the lightweight heat-insulating straw wall bricks in an embodiment of the present invention.

[0042] Figure 4 This is a flowchart illustrating an embodiment of the present invention.

[0043] The reference numerals in the accompanying drawings include: waterproof layer 1, connecting layer 2, solid layer 3, heat insulation layer 4, through hole 5, blocking element 6, connecting element 7, connecting hole 8, and channel 9. Detailed Implementation

[0044] The following detailed description illustrates the specific implementation method:

[0045] Example 1:

[0046] The basics are as follows: Figure 1 , Figure 2 , Figure 3 As shown:

[0047] The lightweight heat-insulating straw wall bricks consist of a waterproof layer 1, a connecting layer 2, a solid layer 3, and several heat-insulating layers 4, from the outside to the inside. The waterproof layer 1 is bonded to the connecting layer 2, the connecting layer 2 is bonded to the solid layer 3, and the solid layer 3 is bonded to the adjacent heat-insulating layer 4. The adjacent heat-insulating layers 4 are integrally formed, and the shape of each heat-insulating layer 4 is wavy.

[0048] The waterproof layer 1 is made of aerogel, the connecting layer 2 is made of foam ceramic, the solid layer 3 is made of straw, and the heat insulation layer 4 is made of vacuum heat insulation material. In this embodiment, the vacuum heat insulation material is vacuum glass.

[0049] The heat insulation layer 4 has several through holes 5 and channels 9, which are distributed alternately from top to bottom. The channels 9 are filled with helium, and the through holes 5 are filled with argon. Several blocking parts 6 of different sizes are bonded to the inside of each through hole 5. Several connectors 7 are integrally formed on one side of the connecting layer 2. Several connecting holes 8 corresponding to the connectors 7 are opened on the side of the connecting layer 2 away from the connectors 7. The connecting holes 8 are connected to the outside.

[0050] The specific implementation process is as follows: When argon gas flows inside the through hole 5, the baffles 6 of different sizes can block the argon gas to a certain extent, thereby slowing down the flow speed of the argon gas, slowing down thermal convection, and increasing the heat insulation performance. At the same time, the different sizes of the baffles 6 result in different blocking effects when the argon gas flows inside the through hole 5. Since the cross-sectional size inside the through hole 5 is different, the argon gas flow rate between different baffles 6 will also be different. The faster-flowing argon gas will drive the slower-flowing argon gas to move together, thereby allowing the argon gas to be evenly distributed inside the through hole 5, reducing the possibility of some argon gas forming dead zones inside the through hole 5.

[0051] After the lightweight insulated straw wall bricks are made, the construction workers can connect them to each other through connector 7 and the connecting hole 8 on another lightweight insulated straw wall brick, which shortens the construction period and reduces labor costs.

[0052] When it rains, the aerogel's excellent hydrophobic properties prevent rainwater from entering the lightweight insulated straw wall bricks, thus protecting them and extending their service life.

[0053] When encountering high temperatures, the lightweight insulated straw wall bricks have relatively small temperature fluctuations due to the excellent thermal insulation properties of aerogel, foam ceramics, vacuum glass, and argon. This reduces the operating time and load of air conditioning and heating systems, achieving energy conservation, emission reduction, and alleviating energy pressure.

[0054] Example 2:

[0055] The basics are as follows: Figure 4 As shown:

[0056] The difference from the above embodiments lies in the production process of lightweight heat-insulating straw wall bricks, which includes the following steps:

[0057] Step 1, crushing and screening: Crush the selected straw and screen it to remove straw particles with a diameter greater than 10mm, and keep straw particles of uniform size.

[0058] Step 2, Raw material drying: The selected straw is dried to control the moisture content of the straw to 7%.

[0059] Step 3, Adding and mixing: Add adhesive and additives to the dried straw raw material and mix thoroughly. The adhesive is a polymeric isocyanate adhesive and the additive is a flame retardant.

[0060] Step 4, Rolling into the mold: Pour the straw with added adhesive and additives into the homogenized plate mold and roll the straw to obtain a straw homogenized plate; Place several vacuum glass pieces into the heat insulation plate mold and press them into a wavy shape; Make several through holes 5 and several channels 9 on the surface of the vacuum glass, and attach several blocking parts 6 inside each through hole 5.

[0061] Step 5, Surface finishing: The surface of the straw homogenized board is finished by first coarse sanding and then fine sanding.

[0062] Step 6, Layer-by-layer installation: Install foam ceramic onto the surface of the straw homogenized plate, install vacuum glass into the straw homogenized plate, and fill each through hole 5 with argon gas for sealing, and fill each channel 9 with helium gas for sealing. Aerogel is used as the sealing material.

[0063] Step 7, 3D printing: Use 3D printing technology to print a waterproof layer 1 on the surface of foam ceramic.

[0064] The specific implementation process is as follows: The staff first crushes the straw and then sieves the straw particles through a sieve plate. After removing straw particles with a diameter greater than 10mm, straw particles of uniform size are selected.

[0065] After selection, the staff put the straw pellets into a dryer for drying, controlling the moisture content of the straw pellets to be 7%. After drying, the staff will add polymeric isocyanate adhesive and flame retardant to the dried straw pellets, and put the mixture of straw pellets, polymeric isocyanate adhesive and flame retardant into a mixer and stir for 10 minutes.

[0066] After mixing, workers placed the mixture of straw pellets, polymeric isocyanate adhesive, and flame retardant into a homogenized plate mold and rolled the mixture in the mold using a roller press to obtain the straw homogenized plate as solid layer 3. After obtaining solid layer 3, workers placed six pieces of vacuum glass into a heat insulation plate mold and rolled them using a roller press to obtain a corrugated heat insulation layer 4. After obtaining the corrugated heat insulation layer 4, workers drilled several through holes 5 and several channels 9 on the heat insulation layer 4, and glued the blocking parts 6 into the inside of the through holes 5. At the same time, argon gas was injected into the through holes 5 and helium gas was injected into the channels 9, and aerogel was used to seal the through holes 5 and channels 9. At this point, because the insulation layer 4 is wavy, the contact area between the solid layer 3 and the insulation layer 4, as well as between adjacent insulation layers 4, increases. This increases the insulation area during heat transfer, enhancing insulation efficiency. Simultaneously, the wavy shape of the insulation layer 4 increases its relative thickness, which in turn increases the length of the through-hole 5. This increases the contact area between argon gas and the through-hole 5, further increasing the insulation area and enhancing insulation efficiency. The design of the through-hole 8 and channel 9 reduces the weight of the lightweight insulating straw wall bricks, giving them a lightweight characteristic. Furthermore, because helium is less dense than air, it accumulates above the channel 9, creating a lifting force on the lightweight insulating straw wall bricks, further reducing their weight.

[0067] The staff removed solid layer 3 and used a wall sander and 50-grit sandpaper to rough sand it for 20 minutes. Then, they used a right-angle sandpaper holder and 180-grit sandpaper to fine sand it for 30 minutes until the surface was smooth.

[0068] The staff placed the wavy insulation layer 4 into the solid layer 3 and bonded it firmly. They then took out the foam ceramic as the connecting layer 2 and bonded it to the surface of the solid layer 3. Finally, they used aerogel as the 3D printing material and used 3D printing technology to print the waterproof layer 1 on the surface of the foam ceramic, thus completing the preparation of the lightweight heat-insulating straw wall brick.

[0069] The above descriptions are merely embodiments of the present invention. Commonly known structures and characteristics are not described in detail here. Those skilled in the art are aware of all common technical knowledge in the field prior to the application date or priority date, are aware of all existing technologies in that field, and have the ability to apply conventional experimental methods prior to that date. Those skilled in the art can, under the guidance of this application, improve and implement this solution in combination with their own capabilities. Some typical known structures or methods should not be obstacles for those skilled in the art to implement this application. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of the present invention. These should also be considered within the scope of protection of the present invention, and will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. Lightweight heat-insulating straw wall bricks, characterized in that: From the outside in, it consists of a waterproof layer, a connecting layer, a solid layer, and several insulation layers. The waterproof layer is fixedly connected to the connecting layer, the connecting layer is fixedly connected to the solid layer, the solid layer is fixedly connected to the adjacent insulation layer, and adjacent insulation layers are fixedly connected to each other. The insulation layers are all wavy in shape. The waterproof layer is made of aerogel, the connecting layer is made of foam ceramic, the solid layer is made of straw, and the insulation layer is made of vacuum insulation material. The insulation layer has several through holes and channels, which are distributed alternately from top to bottom. The channels are filled with helium, and the through holes are filled with argon. Several blocking components of different sizes are fixedly connected inside the through holes.

2. The lightweight heat-insulating straw wall brick according to claim 1, characterized in that: Several connectors are fixedly connected to one side of the connecting layer, and several connecting holes corresponding to the connectors are opened on the side of the connecting layer away from the connecting components, and the connecting holes are connected to the outside.

3. The production process of lightweight heat-insulating straw wall bricks, characterized by: Includes the following steps: Step 1, Material Screening: Crush the selected straw and screen it. Step 2, Raw material drying: The selected straw is dried. Step 3, Adding and mixing: Add binders and additives to the dried straw raw material and mix thoroughly; Step 4, Rolling into the mold: Pour the straw with added adhesive and additives into the homogenized plate mold and roll the straw to obtain a straw homogenized plate; Place a number of vacuum insulation materials into the insulation plate mold and press them into a wavy shape; Make a number of through holes and channels on the surface of the vacuum insulation materials, and fix a number of blocking parts inside each through hole. Step 5, Surface finishing: Grind and finish the surface of the straw homogenization board; Step 6, Layer-by-layer installation: Install foam ceramic onto the surface of the straw homogenous board, install vacuum insulation material into the straw homogenous board, and fill each through hole with argon gas for sealing, and fill each channel with helium gas for sealing. Step 7, 3D printing: Use 3D printing technology to print a waterproof layer on the surface of foam ceramic.

4. The production process of lightweight heat-insulating straw wall bricks according to claim 3, characterized in that: In step one, when screening the straw, straw particles with a diameter greater than 10mm are removed, and straw particles of uniform size are retained.

5. The production process of lightweight heat-insulating straw wall bricks according to claim 4, characterized in that: In step two, when drying the straw, the moisture content of the straw is controlled between 6% and 8%.

6. The production process of lightweight heat-insulating straw wall bricks according to claim 5, characterized in that: In step three, a polymeric isocyanate adhesive is selected as the adhesive.

7. The production process of lightweight heat-insulating straw wall bricks according to claim 6, characterized in that: In step three, flame retardants are selected as additives.

8. The production process of lightweight heat-insulating straw wall bricks according to claim 7, characterized in that: In step five, when grinding the straw homogenized board, first perform coarse grinding, and then perform fine grinding.

9. The production process of lightweight heat-insulating straw wall bricks according to claim 8, characterized in that: In step six, aerogel is used as the sealing material for sealing the through holes and channels.

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