Cement-based imitation brick component and preparation method thereof

Abstract

The invention discloses a cement-based imitation brick component and a preparation method thereof.The cement-based imitation brick component is a flat plate-shaped component, a plurality of grooves are formed in the outer surface of the cement-based imitation brick component, and the outer surface of the cement-based imitation brick component is divided into a plurality of independent protruding blocks through the grooves; the cement-based imitation brick component is made of a fiber reinforced cement composite material. The cement-based imitation brick component provided by the invention is suitable for the fields of various building outer walls, garden landscapes and the like, has the main advantages of light weight, high strength, fire prevention, corrosion resistance, easiness in installation and the like, and also has good environmental protection performance and decorative effect.

Description

Technical Field

[0001] This invention belongs to the field of building materials technology, specifically relating to a cement-based imitation brick component and its preparation method. Background Technology

[0002] Exterior wall tiles are materials used for the decoration and protection of building exteriors, commonly including ceramic exterior wall tiles, glazed tiles, and red bricks. They not only offer aesthetic appeal but also provide certain waterproofing and wear resistance. However, traditional production technologies for ceramic exterior wall tiles, glazed tiles, and red bricks suffer from high energy consumption and significant pollution. Traditional exterior wall tile production requires conventional firing processes, which are energy-intensive and generate large amounts of waste gas and solid waste, causing environmental pollution and making the manufacturing process environmentally unfriendly.

[0003] With increasing environmental awareness and technological advancements, the production and use of exterior wall bricks need continuous improvement and optimization to provide an environmentally friendly exterior wall brick component that effectively reduces environmental impact. Summary of the Invention

[0004] The purpose of this invention is to solve the technical problems of traditional exterior wall bricks, which all require traditional firing processes, resulting in high energy consumption, large amounts of waste gas and solid waste, and environmental pollution. The invention provides a cement-based imitation brick component and its preparation method.

[0005] To solve the above problems, the present invention is implemented according to the following technical solution:

[0006] In a first aspect, the present invention provides a cement-based imitation brick component, wherein the cement-based imitation brick component is a flat plate-shaped component, and the outer surface of the cement-based imitation brick component is provided with multiple grooves, which divide the outer surface of the cement-based imitation brick component into multiple independent protrusions; the cement-based imitation brick component is made of fiber-reinforced cement composite material.

[0007] In conjunction with the first aspect, the present invention also provides a first specific embodiment of the first aspect, wherein the fiber-reinforced cement composite material contains alkali-resistant glass fibers, and the amount of alkali-resistant glass fibers is 2 to 4% of the total weight of the fiber-reinforced cement composite material.

[0008] In conjunction with the first aspect, the present invention also provides a second specific embodiment of the first aspect, wherein, by weight, the fiber-reinforced cement composite material comprises the following components:

[0009]

[0010]

[0011] The fiber-reinforced cement composite material contains color powder, and the amount of color powder is 6% of the weight of cement.

[0012] In this invention, by weight, the cement is 45-55 parts, for example, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, or 55 parts. The quartz sand is 50-60 parts, for example, 51, 52, 53, 54, 55, 56, 57, 58, 59, or 60 parts. The water-reducing agent is 2-2.5 parts, for example, 2.0, 2.1, 2.2, 2.3, 2.4, or 2.5 parts. The defoamer is 0.2-0.3 parts, for example, 0.20, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28, 0.29, or 0.30 parts. The water is 10 to 15 parts, for example, 10, 11, 12, 13, 14 or 15 parts.

[0013] In conjunction with the first aspect, the present invention also provides a third specific embodiment of the first aspect, wherein the quartz sand comprises 26-40 mesh quartz sand, 40-70 mesh quartz sand and 70-120 mesh quartz sand, and the mass ratio of 26-40 mesh quartz sand, 40-70 mesh quartz sand and 70-120 mesh quartz sand is 13.3:29.4:13.3.

[0014] In conjunction with the first aspect, the present invention also provides a fourth specific embodiment of the first aspect, wherein the cement is Albo cement, the water-reducing agent is XS-407 water-reducing agent, and the defoamer is ASK-2 defoamer.

[0015] In conjunction with the first aspect, the present invention also provides a fifth specific embodiment of the first aspect, wherein the cement-based imitation brick component is made by casting fiber-reinforced cement composite material into a precast mold.

[0016] In conjunction with the first aspect, the present invention also provides a sixth specific embodiment of the first aspect, wherein, by weight, the fiber-reinforced cement composite material comprises the following components:

[0017]

[0018] The fiber-reinforced cement composite material contains color powder and adhesive, wherein the amount of color powder is 6% of the weight of cement, and the amount of adhesive is 1L per 25kg of cement.

[0019] In this invention, by weight, the cement is 45-55 parts, for example, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, or 55 parts. The silica sand is 65-75 parts, for example, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, or 75 parts. The water-reducing agent is 1-1.5 parts, for example, 1.0, 1.1, 1.2, 1.3, 1.4, or 1.5 parts. The water is 15-20 parts, for example, 15, 16, 17, 18, 19, or 20 parts.

[0020] In conjunction with the first aspect, the present invention also provides a seventh specific embodiment of the first aspect, wherein the cement-based imitation brick component is made of fiber-reinforced cement composite material using a hot-pressing process.

[0021] Secondly, the present invention also provides a method for preparing the cement-based imitation brick component described in the third to fifth specific embodiments of the first aspect, characterized in that the preparation method includes:

[0022] The raw materials are mixed, water is added in proportion, and the mixture is stirred evenly to obtain fiber-reinforced cement composite material.

[0023] Fiber-reinforced cement composite material is poured into a precast mold, and the mold is vibrated using a tool.

[0024] After pouring, cure at room temperature;

[0025] After curing, the molded cement-based imitation brick components are removed.

[0026] Thirdly, the present invention also provides a method for preparing the cement-based imitation brick component according to the seventh specific embodiment of the first aspect, characterized in that the preparation method includes:

[0027] The raw materials are mixed, water is added in proportion, and the mixture is stirred evenly to obtain fiber-reinforced cement composite material.

[0028] Fiber-reinforced cement composite material is poured into a precast mold;

[0029] The fiber-reinforced cement composite material in the precast mold is hot-pressed using hot-pressing equipment;

[0030] After hot pressing, cure at room temperature;

[0031] After curing, the molded cement-based imitation brick components are removed.

[0032] Compared with the prior art, the beneficial effects of the present invention are:

[0033] This invention provides a cement-based imitation brick component, which is a flat plate-shaped component. The outer surface of the cement-based imitation brick component is provided with multiple grooves, which divide the outer surface of the cement-based imitation brick component into multiple independent protrusions. The cement-based imitation brick component is made of fiber-reinforced cement composite material.

[0034] The cement-based imitation brick component provided by this invention is suitable for various building exterior walls, landscaping, and other fields. Its main advantages include lightweight, high strength, fire resistance, corrosion resistance, and easy installation, while also possessing good environmental performance and decorative effect. By using fiber-reinforced cement composite materials, energy consumption and pollution in traditional firing processes are reduced. The cement-based imitation brick component has the following advantages:

[0035] Environmental friendliness: Because it does not rely on high-temperature firing, it reduces pollution to the environment and meets the requirements of green building.

[0036] Energy efficiency: The production process consumes less energy, which helps to reduce overall energy consumption.

[0037] Aesthetics: The surface of the component has multiple grooves forming several independent protrusions, which can imitate the appearance of traditional red bricks and meet the decorative needs of the building.

[0038] Excellent physical properties: Fiber-reinforced cement composites have good durability. Cement-based imitation brick components are made of fiber-reinforced cement composites. The fiber reinforcement method can effectively improve the flexural strength and toughness of cement-based imitation brick components.

[0039] Lightweight: Compared to traditional building materials such as rainbow bricks, these cement-based components are generally lighter, making them easier to construct and transport. Attached Figure Description

[0040] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings, wherein:

[0041] Figure 1 This is a front view of the cement-based imitation brick component of the present invention;

[0042] Figure 2 This is a side view of the cement-based imitation brick component of the present invention;

[0043] Figure 3 This is a cross-sectional schematic diagram of the cement-based imitation brick component of the present invention;

[0044] Figure 4 This is an assembly diagram of the cement-based imitation brick component of the present invention;

[0045] Figure 5 This is a test curve diagram of the cement-based imitation brick component cast in Embodiment 1 of the present invention;

[0046] Figure 6 This is a test curve diagram of the cement-based imitation brick component hot-pressed according to Embodiment 2 of the present invention. Detailed Implementation

[0047] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0048] Currently, traditional red bricks and ceramic tiles are the main products used as wall tiles. From a technical perspective, although the production technology of traditional red bricks and ceramic tiles has been continuously improved and optimized, some shortcomings still exist. For example, the firing process of red bricks requires a large amount of coal resources, and the high firing temperature and long firing time result in high energy consumption. In addition, red bricks have low compressive strength and are easily affected by external environmental factors, leading to cracking and detachment. Ceramic tile production also has similar problems, such as high energy consumption and heavy pollution. With the increasing awareness of environmental protection and technological advancements, the production and use of exterior wall tiles also need continuous improvement and optimization to provide an environmentally friendly exterior wall tile component that effectively reduces environmental impact.

[0049] Therefore, this invention provides a cement-based imitation brick component, which is a flat, plate-like component. The outer surface of the cement-based imitation brick component has multiple grooves, which divide the outer surface into multiple independent protrusions. The cement-based imitation brick component is made of fiber-reinforced cement composite material. The cement-based imitation brick component provided by this invention is suitable for various building exterior walls, landscaping, and other fields. Its main advantages are lightweight, high strength, fire resistance, corrosion resistance, and easy installation, while also possessing good environmental performance and decorative effect.

[0050] In the first embodiment, the present invention provides a cast-in-place cement-based imitation brick component, which is made by casting fiber-reinforced cement composite material into a precast mold. The fiber-reinforced cement composite material comprises the following components by weight:

[0051]

[0052]

[0053] The fiber-reinforced cement composite material contains alkali-resistant glass fibers, and the amount of alkali-resistant glass fibers is 2% of the total weight of the fiber-reinforced cement composite material. The fiber-reinforced cement composite material contains color powder, and the amount of color powder is 6% of the weight of cement.

[0054] In specific implementation, the quartz sand includes 26-40 mesh quartz sand, 40-70 mesh quartz sand, and 70-120 mesh quartz sand, with a mass ratio of 13.3:29.4:13.3. Preferably, Albo cement is used, XS-407 water-reducing agent is used, and ASK-2 defoamer is used.

[0055] In the first embodiment, the present invention also provides a method for preparing a cement-based imitation brick component, the method comprising:

[0056] S1: Mix the raw materials of each component, add water in proportion, and stir evenly to obtain fiber-reinforced cement composite material.

[0057] S2: Pour the fiber-reinforced cement composite material into the precast mold and vibrate the mold using a tool;

[0058] S3: After pouring, cure at room temperature;

[0059] S4: After curing, demold and remove the formed cement-based imitation brick component.

[0060] In a second embodiment, the present invention provides a hot-pressed cement-based imitation brick component, which is made of fiber-reinforced cement composite material using a hot-pressing process. The fiber-reinforced cement composite material comprises the following components by weight:

[0061]

[0062] The fiber-reinforced cement composite material contains alkali-resistant glass fibers, and the amount of alkali-resistant glass fibers is 6% of the total weight of the fiber-reinforced cement composite material. The fiber-reinforced cement composite material contains color powder and adhesive, and the amount of color powder is 6% of the weight of cement, and the amount of adhesive is 1L per 25kg of cement.

[0063] In practice, Albo cement is used, and polycarboxylate superplasticizer is used. Specifically, No. 5 and No. 7 silica sand are used.

[0064] In a second embodiment, the present invention also provides a method for preparing a cement-based imitation brick component, the method comprising:

[0065] S10: Mix the raw materials of each component, add water in proportion, and stir evenly to obtain fiber-reinforced cement composite material.

[0066] S20: Pour the fiber-reinforced cement composite material into the precast mold;

[0067] S30: A hot pressing device is used to hot press the fiber-reinforced cement composite material in the precast mold. In one specific implementation, the production equipment is a brick press. The main air pressure gauge of the brick press is vented and the pressure is maintained at 0.18-0.2 MPa. The pressure gauge on the oil-water separator of the palletizer is vented and the pressure is maintained at 0.4-0.6 MPa. The cooling water circulation system is turned on to ensure that the working temperature of the brick press is between 10 and 50°C.

[0068] S40: After hot pressing, cure at room temperature;

[0069] S50: After curing, demold and remove the formed cement-based imitation brick component.

[0070] Specifically, the present invention provides the following preparation examples for further illustration:

[0071] Example 1

[0072] This embodiment provides a cement-based imitation brick component, such as... Figure 1 , Figure 2 and Figure 3 As shown, the cement-based imitation brick component is a flat plate-shaped component. The outer surface of the cement-based imitation brick component is provided with multiple grooves, which divide the outer surface of the cement-based imitation brick component into multiple independent protrusions.

[0073] In practice, the cement-based imitation brick component has a length of 990mm, a width of 490mm, and a thickness of 25mm. The groove is 10mm wide and its depth is half the thickness of the cement-based imitation brick component.

[0074] In practice, the outer contour of the protrusion is a rectangle with a length of 240mm and a width of 60mm, and the thickness of the block is half the thickness of the cement-based imitation brick component.

[0075] The cement-based imitation brick component is made of fiber-reinforced cement composite material, which comprises the following components by weight:

[0076]

[0077] The fiber-reinforced cement composite material contains color powder, and the amount of color powder is 6% of the weight of cement. The fiber-reinforced cement composite material also contains alkali-resistant glass fiber, and the amount of alkali-resistant glass fiber is 2% of the total weight of the fiber-reinforced cement composite material.

[0078] Specifically, the quartz sand includes 26-40 mesh quartz sand, 40-70 mesh quartz sand, and 70-120 mesh quartz sand, with a mass ratio of 13.3:29.4:13.3. Specifically, the addition amount of 26-40 mesh quartz sand is 13.3 kg, the addition amount of 40-70 mesh quartz sand is 29.4 kg, and the addition amount of 70-120 mesh quartz sand is 13.3 kg.

[0079] Specifically, Albo cement is used, XS-407 water-reducing agent is used, and ASK-2 defoamer is used.

[0080] This embodiment also provides a method for preparing cement-based imitation brick components, wherein the preparation method involves casting using a precast mold, and the preparation method includes:

[0081] 1. Raw material preparation: Prepare the above-mentioned raw materials such as cement, quartz sand, fiber, and additives. The selection and quality of these materials will directly affect the performance and quality of the final product.

[0082] 2. Mixing and Stirring: Mix the raw materials according to the above weights, add water and stir to obtain fiber-reinforced cement composite material. The purpose of stirring is to ensure that the raw materials are fully and evenly mixed to ensure the uniformity and consistency of the product.

[0083] 3. Mold Preparation: A matching mold is prepared based on the shape and size of the imitation brick product. The mold can be made of materials such as wood, plastic, or metal. The mold consists of a matching lower mold and an upper mold. The lower mold serves as a container for the fiber-reinforced cement composite material, while the upper mold has structures for forming grooves and protrusions.

[0084] 4. Casting and molding: Pour the mixed fiber-reinforced cement composite material into the precast mold, and use tools such as vibrators to remove air bubbles to ensure that the fiber-reinforced cement composite material fully fills the mold.

[0085] 5. Curing: After pouring, place the mold in a suitable environment for curing. The purpose of curing is to allow the fiber-reinforced cement composite to fully harden and solidify to achieve the expected strength and performance.

[0086] In practice, curing and hardening can be carried out using a curing device, which includes a constant temperature chamber and a humidifier. The constant temperature chamber controls the internal temperature to ensure that the component hardens at a constant temperature, while the humidifier maintains the humidity inside the chamber to prevent the component from drying out and cracking. In one specific embodiment, the hardening treatment temperature is maintained at 20±2℃, and the humidity is 90%.

[0087] 6. Demolding: After the curing period, open the mold and remove the formed cement-based imitation brick component.

[0088] In a preferred embodiment, the preparation method further includes a post-processing step, specifically including:

[0089] 7. Repair and polishing: Perform surface treatment on the removed cement-based imitation brick components, such as cleaning surface residues and polishing, to make the surface smooth and clean.

[0090] 8. Secondary curing and hardening: Continue curing and hardening treatment to ensure that the cement-based imitation brick components achieve better strength and durability.

[0091] In practice, curing and hardening can be carried out using a curing device, which includes a constant temperature chamber and a humidifier. The constant temperature chamber controls the internal temperature to ensure that the component hardens at a constant temperature, while the humidifier maintains the humidity inside the chamber to prevent the component from drying out and cracking. In one specific embodiment, the hardening treatment temperature is maintained at 20±2℃, and the humidity is 90%.

[0092] 9. Surface treatment: Depending on the product requirements, surface coating, mortar spraying, texture processing and other processes can be carried out to enhance the aesthetics of cement-based imitation brick components.

[0093] 10. Inspection and Packaging: Conduct quality inspections on the finished products, including testing for dimensions, strength, appearance, and other indicators. Finally, package the products for transportation and sale.

[0094] Product Experiment:

[0095] (I) Bending test of cement-based imitation brick components

[0096] According to the standard BS EN 1170-4:1998, based on the formulation and preparation method of Example 1, eight samples (T1, T2, T3, T4, B1, B2, B3, and B4) were prepared and subjected to bending tests. Figure 5 The test data for cement-based imitation brick components are as follows:

[0097]

[0098] Example 2

[0099] This second embodiment provides a cement-based imitation brick component, such as... Figure 1 , Figure 2 and Figure 3 As shown, the cement-based imitation brick component is a flat plate-shaped component. The outer surface of the cement-based imitation brick component is provided with multiple grooves, which divide the outer surface of the cement-based imitation brick component into multiple independent protrusions.

[0100] In practice, the cement-based imitation brick component has a length of 990mm, a width of 490mm, and a thickness of 25mm. The groove is 10mm wide and its depth is half the thickness of the cement-based imitation brick component.

[0101] In practice, the outer contour of the protrusion is a rectangle with a length of 240mm and a width of 60mm, and the thickness of the block is half the thickness of the cement-based imitation brick component.

[0102] The cement-based imitation brick component is made of fiber-reinforced cement composite material, which comprises the following components by weight:

[0103]

[0104] The fiber-reinforced cement composite material contains color powder, and the amount of color powder is 6% of the weight of cement. The fiber-reinforced cement composite material also contains alkali-resistant glass fiber, and the amount of alkali-resistant glass fiber is 6% of the total weight of the fiber-reinforced cement composite material.

[0105] Specifically, the silica sand includes 50 kg of No. 5 silica sand (20-40 mesh) and 20 kg of No. 7 silica sand (60-150 mesh). Specifically, Albo cement is used, and polycarboxylate superplasticizer is used.

[0106] This embodiment two also provides a method for preparing cement-based imitation brick components, wherein the preparation method is a hot pressing molding process, and the preparation method includes:

[0107] 1. Raw material preparation: Prepare the above-mentioned raw materials such as cement, silica sand, fiber, and additives. The selection and quality of these materials will directly affect the performance and quality of the final product.

[0108] 2. Mixing: Pour the raw materials into a mixer according to the above weights, add water, and mix to obtain fiber-reinforced cement composite material. The purpose of mixing is to ensure that the raw materials are fully and evenly mixed to ensure the uniformity and consistency of the product.

[0109] 3. Mold Preparation: A matching mold is prepared based on the shape and size of the imitation brick product. The mold can be made of materials such as wood, plastic, or metal. The mold serves as a container for the fiber-reinforced cement composite material.

[0110] 4. Compression Molding: The well-mixed fiber-reinforced cement composite material is placed into a mold and then compressed. This step typically employs a hot-pressing process, where the mold is placed in the ceramic tile production equipment, and heat and pressure are used to cure the fiber-reinforced cement composite material, resulting in the desired shape and texture.

[0111] In one specific implementation, the production equipment is a brick press. The main air pressure gauge of the brick press is vented and the pressure is maintained at 0.18-0.2 MPa, while the pressure gauge on the oil-water separator of the palletizer is vented and the pressure is maintained at 0.4-0.6 MPa. The cooling water circulation system is turned on to ensure that the operating temperature of the brick press is between 10 and 50°C.

[0112] 5. Curing and Maintenance: After hot pressing, the cement-based imitation brick components need to be cured to achieve a certain strength and stability. Room temperature curing is generally used, and the time depends on the specific requirements and thickness of the product, typically requiring 1-2 days.

[0113] (I) Bending test of cement-based imitation brick components

[0114] According to the standard BS EN 1170-4:1998, and based on the formulation and preparation method of Example 2, eight samples (T1, T2, T3, T4, B1, B2, B3, and B4) were prepared and subjected to bending tests. Figure 6 The test data for cement-based imitation brick components are as follows:

[0115]

[0116] Other structures of the cement-based imitation brick component and its preparation method described in this embodiment are found in the prior art.

[0117] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Therefore, any modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A cement-based imitation brick component, characterized in that: The cement-based imitation brick component is a flat plate-shaped component. The outer surface of the cement-based imitation brick component is provided with multiple grooves, which divide the outer surface of the cement-based imitation brick component into multiple independent protrusions. The cement-based imitation brick component is made of fiber-reinforced cement composite material.

2. The cement-based imitation brick component according to claim 1, characterized in that: The fiber-reinforced cement composite material contains alkali-resistant glass fibers, and the amount of alkali-resistant glass fibers is 2 to 4% of the total weight of the fiber-reinforced cement composite material.

3. A cement-based imitation brick component according to claim 2, characterized in that, The fiber-reinforced cement composite material comprises the following components in parts by weight: The fiber-reinforced cement composite material contains color powder, and the amount of color powder is 6% of the weight of cement.

4. A cement-based imitation brick component according to claim 3, characterized in that: The quartz sand includes 26-40 mesh quartz sand, 40-70 mesh quartz sand and 70-120 mesh quartz sand, and the mass ratio of 26-40 mesh quartz sand, 40-70 mesh quartz sand and 70-120 mesh quartz sand is 13.3:29.4:13.

3.

5. A cement-based imitation brick component according to claim 3, characterized in that: The cement used is Albo cement, the water-reducing agent is XS-407 water-reducing agent, and the defoamer is ASK-2 defoamer.

6. A cement-based imitation brick component according to any one of claims 3 to 5, characterized in that: The cement-based imitation brick component is made by casting fiber-reinforced cement composite material into a precast mold.

7. A cement-based imitation brick component according to claim 2, characterized in that, The fiber-reinforced cement composite material comprises the following components in parts by weight: The fiber-reinforced cement composite material contains color powder and adhesive, wherein the amount of color powder is 6% of the weight of cement, and the amount of adhesive is 1L per 25kg of cement.

8. A cement-based imitation brick component according to claim 7, characterized in that: The cement-based imitation brick component is made of fiber-reinforced cement composite material using a hot-pressing process.

9. A method for preparing a cement-based imitation brick component according to claim 6, characterized in that, The preparation method includes: The raw materials are mixed, water is added in proportion, and the mixture is stirred evenly to obtain fiber-reinforced cement composite material. Fiber-reinforced cement composite material is poured into a precast mold, and the mold is vibrated using a tool. After pouring, cure at room temperature; After curing, the molded cement-based imitation brick components are removed.

10. A method for preparing a cement-based imitation brick component according to claim 8, characterized in that, The preparation method includes: The raw materials are mixed, water is added in proportion, and the mixture is stirred evenly to obtain fiber-reinforced cement composite material. Fiber-reinforced cement composite material is poured into a precast mold; The fiber-reinforced cement composite material in the precast mold is hot-pressed using hot-pressing equipment; After hot pressing, cure at room temperature; After curing, the molded cement-based imitation brick components are removed.

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