Preparation process of high-temperature flexural strength magnesia carbon brick

Abstract

The invention relates to the technical field of magnesia carbon brick production, in particular to a preparation process of a high-temperature flexural strength magnesia carbon brick. A pre-pressing step; a roughening step; and a pressing step: matching a pre-pressing mechanism, a coarsening mechanism and a pressing mechanism. Two key areas of a magnesia carbon brick framework and an impact surface are pre-pressed by using a new material as a raw material, and a reclaimed material is used as a filler, so that the strength is improved while the performance of the magnesia carbon brick is ensured, and the technical problem that the performance of the reclaimed material magnesia carbon brick is poorer and unstable is solved.

Description

Technical Field

[0001] This invention relates to the field of magnesia-carbon brick production technology, and in particular to a preparation process for high-temperature flexural strength magnesia-carbon bricks. Background Technology

[0002] Magnesia-carbon bricks are non-burning carbon composite refractory materials made from high-melting-point basic oxide magnesium oxide (melting point 2800℃) and high-melting-point carbon materials that are difficult to be wetted by slag, with the addition of various non-oxide additives. They are bonded together with carbonaceous binders. Magnesia-carbon bricks are mainly used as linings in converters, AC electric arc furnaces, and DC electric arc furnaces, as well as in the slag line of steel ladles.

[0003] Magnesia-carbon bricks, as a composite refractory material, effectively utilize the strong slag erosion resistance of magnesia and the high thermal conductivity and low expansion of carbon, compensating for the biggest drawback of magnesia's poor spalling resistance. Their main characteristics include: good high-temperature resistance, strong slag resistance, good thermal shock resistance, and low high-temperature creep.

[0004] However, in actual production, when using recycled materials from waste bricks for secondary production of magnesia-carbon bricks, the quality is greatly affected by the quality of the waste bricks and the performance is inferior to that of virgin bricks, which is not conducive to reducing costs and meeting environmental protection requirements. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings of existing technologies by setting up a pre-compression step and a roughening step, using virgin material as raw material to pre-compress the two key areas of the magnesia-carbon brick skeleton and the impact surface, and using recycled material as filler, thereby ensuring the performance of the magnesia-carbon brick while improving its strength, thus solving the technical problem of poor and unstable performance of recycled material magnesia-carbon bricks.

[0006] To address the above technical issues, the following technical solution is adopted: A process for preparing high-temperature flexural strength magnesia-carbon bricks includes: Step one, the recycling step, involves recycling waste magnesia-carbon bricks to form recycled materials; Step 2, Pre-compression step: Use new materials to pre-compress into skeleton and impact surface, and add fibers during the pressing of impact surface to seal the pores on impact surface and enhance impact surface strength. Step 3, roughening step, uses methods such as pressure rollers, scrapers, needle punching, and brushes to roughen the surface of the pre-pressed skeleton and the pressing surface of the impact surface, making the pressing surface rough and uneven, while adhering large particles of new material to the surface of the skeleton. Step four, the pressing step, combines the skeleton with the impact surface, and simultaneously opens holes in the skeleton and the impact surface. The mortise and tenon structure is used to enhance the bonding strength. It is then moved into the mold, and the empty parts are filled with recycled material, so that the impact surface presents a multi-layer buffer structure of "new material - new and old mixture - recycled material".

[0007] Preferably, the preparation process of the high-temperature flexural strength magnesia-carbon brick includes a waste recycling device applied in step one and a pre-compression mechanism applied in step two. The pre-compression mechanism is located behind the waste recycling device and includes a first press for pre-compressing the skeleton, a second press for pre-compressing the impact surface, a clamping arm for clamping the skeleton and the impact surface, and a pre-compression component set on the second press for adding fibers to the impact surface. The first press and the second press are equipped with pre-press molds for pressing out the skeleton and the impact surface into corresponding shapes, respectively, and the pressing blocks of the molds are equipped with negative pressure devices. The first and second presses pre-press the magnesia-carbon brick skeleton and impact surface using new materials. While pressing the impact surface, negative pressure is used to assist the discharge of internal gas and simultaneously adsorb the fibers into the pores formed by the gas discharge, thereby sealing the pores. At the same time, the fibers form anchors to strengthen the bonding strength between the impact surface and the material behind it.

[0008] Preferably, the pre-compression assembly includes a perforated plate disposed on the pre-compression mold and having a square hole in the middle, two sets of partitions slidably connected below the perforated plate, a fiberboard disposed below the partitions and having the same square hole in the middle, air jets disposed on both sides of the fiberboard, a cover plate slidably connected to the bottom of the fiberboard, a supplementary cavity slidably connected to the bottom of the fiberboard, and a pressure plate disposed at the bottom of the supplementary cavity. New material is filled into the pre-compression mold, and then a pre-compression is performed to expel a large amount of air from the new material, forming pores. At this time, the fiber is still in a fluffy state. Then, negative pressure is used to adsorb the fiber into the pores, and the remaining raw material is added for a second extrusion to complete the initial forming of the impact surface.

[0009] Preferably, the roughening mechanism applied in step three is located behind the pre-compression mechanism and performs different roughening treatments on the skeleton and the impact surface, including a first roughening component for roughening the impact surface and a second roughening component for roughening the skeleton. The roughening mechanism loosens the pre-compressed skeleton and the back of the impact surface, keeping the surface uneven. This allows the new and recycled materials to mix and interlock during the subsequent pressing process, thus enhancing the pressing strength.

[0010] Preferably, the first roughening component includes a placement plate disposed behind the second press and having a passage opening in the middle, a needle plate vertically and slidably connected above the placement plate, multiple sets of first grinding rollers rotatably connected to the middle of the needle plate, and multiple sets of brushes slidably connected around the passage opening. After the impact surface is pre-pressed, the side of the impact surface that is not impacted is needled using a needle punch, and the surface is loosened again using a brush. The back of the impact surface and the part where it meets the skeleton are then rolled by a roller to make the surface uneven. This helps to improve the bonding strength during the pressing process, while the swept-out waste material forms a multi-layer buffer structure for the impact surface.

[0011] Preferably, the second roughening component includes a clamping member slidably connected above the first roughening component, a roughening member disposed on the moving path of the clamping member, and an adhesive attachment; The clamping component includes a slide table slidably connected above the first roughening component, a fixed frame rotatably connected to the slide table, multiple support rods rotatably connected to the bottom of the fixed frame, multiple clamping rods slidably connected to both sides of the fixed frame, and a pressure rod rotatably connected to the upper end of the clamping rods.

[0012] Preferably, the roughening component includes a splash guard disposed above the slide table, a collection trough disposed below the splash guard, a central roughening frame slidably connected in the middle of the splash guard, multiple sets of second grinding rollers rotatably connected to the lower part of the central roughening frame, a crushing plate rotatably connected to the upper end of the central roughening frame, two sets of edge roughening frames slidably connected to both ends of the central roughening frame, and a crushing blade slidably connected to the edge roughening frame.

[0013] Preferably, the adhesive attachment is located behind the roughening part and includes a discharge port located on top of the splash guard and a nozzle located below the discharge port and on the collection tank. The pre-compressed skeleton is moved, and each surface of the skeleton is roughened. The falling waste material is collected, and then a binder is used to adhere large aggregate particles to the surface of the skeleton. This allows the recycled fine material to be embedded in the middle of the large particles in the subsequent pressing step. The surface of the new material skeleton and the recycled material achieve a tenon-and-mortise interlocking effect, which enhances the bonding strength.

[0014] Preferably, the pressing mechanism applied in step four is located below the pre-pressing mechanism and the roughening mechanism, and includes a pressing machine, a pressing mold slidably connected to the pressing machine, and a filling component located behind the roughening mechanism.

[0015] As another preferred embodiment, the filling assembly includes a side plate placed on the moving path of the pressing mold, grippers slidably connected to both sides of the side plate, a drill bit slidably connected to one side of the side plate, a block slidably connected to the other side of the side plate, a discharge pipe placed above the side plate, and a recovery pipe communicating with the collection trough. The pressing mechanism transfers the skeleton to the pressing mold and drills holes at the joint between the skeleton and the impact surface. It releases some recycled material into the enclosure and mixes this recycled material with the scattered new material on the impact surface to form a mixed buffer layer. Then, a large amount of recycled material is released to fill the skeleton and squeezed into the drilled holes to form a tenon-and-mortise connection between the skeleton, the recycled material filler and the impact surface, and then proceeds to complete the pressing and molding process.

[0016] The beneficial effects of this invention are: (1) In this invention, the two key components of the magnesia-carbon brick are the "skeleton" and the "impact surface" that directly bears the impact, which are pre-pressed with new material, and the internal filling is recycled material. This improves the performance stability and key area strength of the recycled material magnesia-carbon brick, effectively solving the technical problem that the performance of traditional recycled material magnesia-carbon brick is greatly affected by the quality of waste brick and the performance is unstable. This method ensures that the overall performance of the brick is close to that of the new material brick, while significantly reducing the raw material cost and environmental burden. (2) In this invention, negative pressure technology is innovatively used during the pre-compression process of the impact surface. This technology helps to expel the gas in the raw material on the one hand, and uses negative pressure to actively adsorb and anchor the fibers in the micropores formed after the gas is discharged on the other hand. This not only seals the pores and avoids weakening the strength of the material, but also forms a unique "fiber anchor" structure, which greatly enhances the strength of the impact surface itself and the mechanical interlocking and bonding strength between it and the subsequent recycled material filling layer from a microscopic perspective; (3) In this invention, the joint surface of the skeleton and the impact surface is specially treated through a roughening step to make its surface rough and loose. At the same time, large-particle aggregate is adhered to the surface of the skeleton. This significantly increases the contact area and interlocking ability between the new material and the recycled material, so that the two form a strong interlocking structure similar to "mortise and tenon" after pressing. In addition, the transitional buffer layer of "new material-new and old mixture-recycled material" naturally formed by the process can effectively disperse and absorb thermal stress and mechanical impact, prevent interlayer peeling, and improve the thermal shock resistance and overall durability of the brick. (4) In this invention, by drilling holes at the junction of the skeleton and the impact surface and filling them with recycled materials to form mortise and tenon connections, macroscopic mechanical interlocking between components is achieved, further consolidating the structural integrity. The entire process system also includes a waste collection and reuse process, which improves the utilization rate of raw materials and reduces waste, so that the preparation process can improve product performance while also having good economic and environmental benefits.

[0017] In summary, this equipment has the advantages of high production stability, environmental friendliness, low cost and high degree of automation, and is especially suitable for the field of magnesia-carbon brick production technology. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the preparation process of a high-temperature flexural strength magnesia-carbon brick.

[0020] Figure 2 This is a schematic diagram of the overall structure of the equipment used in the preparation of high-temperature flexural strength magnesia-carbon bricks.

[0021] Figure 3 This is a schematic diagram of part of the equipment used in the preparation process of high-temperature flexural strength magnesia-carbon bricks.

[0022] Figure 4 This is a schematic diagram of the pre-compression mechanism.

[0023] Figure 5 This is a partial structural diagram of the pre-compression component.

[0024] Figure 6 This is a schematic diagram of the cross-section of the preloaded component.

[0025] Figure 7 This is a schematic diagram of the structure of the first coarsening component.

[0026] Figure 8 This is a schematic diagram of the structure of the second coarsening component.

[0027] Figure 9 This is a schematic diagram of the clamping component.

[0028] Figure 10 This is a structural schematic diagram of the roughened part.

[0029] Figure 11 This is a schematic diagram of the relevant structure of the adhesive attachment.

[0030] Figure 12 This is a schematic diagram of the overall structure of the pressing mechanism.

[0031] Figure 13 This is a structural diagram of the filling component. Detailed Implementation

[0032] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

[0033] Example 1 like Figure 1 , Figure 13 As shown, a process for preparing a high-temperature flexural strength magnesia-carbon brick includes: Step one, the recycling step, involves recycling waste magnesia-carbon bricks to form recycled materials; Step 2, Pre-compression step: Use new materials to pre-compress into skeleton and impact surface, and add fibers during the pressing of impact surface to seal the pores on impact surface and enhance impact surface strength. Step 3, roughening step, uses methods such as pressure rollers, scrapers, needle punching, and brushes to roughen the surface of the pre-pressed skeleton and the pressing surface of the impact surface, making the pressing surface rough and uneven, while adhering large particles of new material to the surface of the skeleton. Step four, the pressing step, combines the skeleton with the impact surface, and simultaneously opens holes in the skeleton and the impact surface. The mortise and tenon structure is used to enhance the bonding strength. It is then moved into the mold, and the empty parts are filled with recycled material, so that the impact surface presents a multi-layer buffer structure of "new material - new and old mixture - recycled material".

[0034] In this embodiment, a novel recycled material magnesia-carbon brick production process is provided, which reduces the production cost of magnesia-carbon bricks while improving their strength, ensuring their high-temperature and impact resistance, and improving economic efficiency.

[0035] In detail, the core of the current production process for recycled magnesia-carbon bricks lies in the meticulous processing and scientific formulation of the recycled waste bricks. The main steps include: manually sorting the waste bricks to remove surface slag and metallic impurities; then subjecting them to multi-stage crushing and magnetic separation; followed by heating and drying to remove structural water; and finally, sieving to obtain recycled materials of different particle sizes. During production, these recycled materials are mixed with some new raw materials (such as fused magnesia), binders (such as phenolic resin), and antioxidants in specific proportions; finally, the mixture is high-pressure molded and heat-treated to obtain the finished product.

[0036] Compared to magnesia-carbon bricks made from virgin materials, recycled magnesia-carbon bricks offer significant advantages in reducing raw material costs and solid waste emissions, resulting in substantial environmental and economic benefits. Ideally, their performance (such as slag erosion resistance and service life) can approach or even reach the level of new bricks. However, their disadvantages include a more complex production process, higher requirements for pretreatment (such as removing aluminum carbide that causes brick cracking), and the performance stability of recycled bricks being influenced to some extent by the source and quality of the waste bricks.

[0037] Based on the shortcomings of recycled magnesia-carbon bricks, this application uses virgin material as the impact surface and skeleton of magnesia-carbon bricks, and uses recycled material as internal filling support. The virgin material ensures the strength and erosion resistance of key areas, while the recycled material as filler significantly reduces costs and makes the overall performance more stable and reliable. It no longer relies excessively on the quality of waste bricks, realizes high-value recycling of refractory materials, and reduces resource waste and solid waste emissions.

[0038] Example 2 like Figures 2-13 As shown, components that are the same as or corresponding to those in Embodiment 1 are referred to using the same reference numerals as in Embodiment 1. For simplicity, only the differences from Embodiment 1 are described below. The difference between Embodiment 2 and Embodiment 1 is as follows: Furthermore, such as Figure 2 , Figure 3 , Figure 4 As shown, the preparation process of a high-temperature flexural strength magnesia-carbon brick includes a waste recycling device 01 applied in step one, and a pre-compression mechanism 1 applied in step two. The pre-compression mechanism 1 is located behind the waste recycling device 01 and includes a first press 11 for pre-compressing the skeleton, a second press 12 for pre-compressing the impact surface, a clamping arm 13 for clamping the skeleton and the impact surface, and a pre-compression component 14 disposed on the second press 12 for adding fibers to the impact surface. The first press 11 and the second press 12 are equipped with pre-press molds 111 for pressing out the shapes corresponding to the skeleton and the impact surface, respectively, and the pressing blocks of the molds are equipped with negative pressure devices. The first press 11 and the second press 12 pre-press out the magnesia-carbon brick skeleton and the impact surface using new materials. While pressing the impact surface, negative pressure is used to assist the discharge of internal gas and at the same time adsorb the fibers into the pores formed by the gas discharge, thereby sealing the pores. At the same time, the fibers form anchor rods to strengthen the bonding strength between the impact surface and the material behind it.

[0039] Furthermore, such as Figure 5 , Figure 6 As shown, the pre-compression assembly 14 includes a perforated plate 141 with a square hole in the middle, disposed on the pre-compression mold 111; two sets of partitions 142 slidably connected below the perforated plate 141; a fiberboard 143 with the same square hole in the middle, disposed below the partitions 142; air jets 144 disposed on both sides of the fiberboard 143; a cover plate 145 slidably connected to the bottom of the fiberboard 143; a supplementary cavity 146 slidably connected to the bottom of the fiberboard 143; and a pressure plate 147 disposed at the bottom of the supplementary cavity 146. New material is filled into the pre-compression mold 111, and then a pre-compression is performed to expel a large amount of air from the new material and form pores. At this time, the fiber is still in a fluffy state. Then, negative pressure is used to adsorb the fiber into the pores, and the remaining raw material is added for a second extrusion to complete the initial forming of the impact surface.

[0040] In detail, in the existing technology, raw materials are filled into a mold for hot pressing. During the pressing process, the gas in the middle of the raw materials is discharged, leaving pores inside. Pores will cause the material to become less hard, less strong, and less impact-resistant. Especially for the impact surface area that is directly subjected to thermal shock, the presence of pores will greatly shorten the life of magnesia-carbon bricks.

[0041] This application separately presses the virgin material into two key components: a skeleton and an impact surface. The ingenuity of this separate design lies in its ability to differentiate the functional requirements of different parts. The skeleton serves as the load-bearing support structure of the magnesia-carbon brick, while the impact surface is the critical area directly facing the thermal shock of the slag. Both are pressed using virgin material with more stable performance. Particularly for the impact surface, a negative pressure system is introduced into the pre-pressing process, which is the key innovation of the entire technology. Under negative pressure, uniformly distributed micropores form on the surface of the impact surface, simultaneously releasing fibrous material. These fibers, under the attraction of the negative pressure, vertically insert into the pores, forming a unique fiber anchor structure.

[0042] In this application, new material is released into the first press 11 and the second press 12. The first press 11 pre-presses out the skeleton, and the second press pre-presses out the impact surface. A negative pressure device is provided on the pressure block above the first press 11 and the second press 12 to reduce the size of the pores and keep the pores uniform. The shape of the skeleton can be set as two vertical crosses that overlap in the middle. In order to achieve better subsequent bonding and transfer of the impact surface, a contact block that bonds with the skeleton is provided in the middle of the back of the impact surface. The corresponding ends of the contact block and the skeleton should be set as protrusions and grooves that can fit into each other, so as to facilitate subsequent tenon and mortise fitting and strengthen the bonding strength.

[0043] It should be noted that, for the pressing of the impact surface, the new material is released onto the perforated plate 141 of the pre-pressing mold 111. At this time, the partition 142 at the bottom of the perforated plate 141 is closed, and the second press 12 performs a pre-pressing. After the pre-pressing is completed, the partition 142 is opened, and the air jets 144 on both sides of the fiberboard 143 work together to blow air onto the fibers on the limiting plate. At the same time, with the help of the negative pressure device of the pressure block above the impact surface, some fibers pass through the perforated plate 141 and are inserted into the impact surface. At this time, the impact surface has formed air holes, but since it is not completely compacted, the fibers can be attracted by the negative pressure and enter the impact surface. Then, the cover plate 145 on the fiberboard 143 is opened, and the replenishing cavity 146 is also replenished with new material. The replenishing cavity 146 moves upward, and the pressure plate 147 at the bottom also moves upward, pressing the new material inside into the impact surface that has been initially formed above, as a contact block for bonding with the skeleton. Then, a second pre-pressing is performed to pre-press and form the impact surface.

[0044] It is worth mentioning that inserting fibers into the impact surface has a dual function: on the one hand, the fiber anchors provide mechanical anchoring points for subsequent bonding and fixing, enhancing the bonding strength between different material layers; on the other hand, the insertion of fibers effectively blocks pores, avoiding the problem of insufficient strength in traditional porous materials, and significantly enhancing the overall strength of the impact surface.

[0045] The perforated plate 141 creates numerous protrusions on the back side of the impact surface during the pressing process, making it easier for the material to become looser during subsequent roughening and allowing for tighter bonding between the raw materials during the pressing process. Furthermore, such as Figure 3 , Figure 7 , Figure 8 As shown, the roughening mechanism 2 applied in step three is located behind the pre-compression mechanism 1 and performs different roughening treatments on the skeleton and the impact surface, including a first roughening component 21 for roughening the impact surface and a second roughening component 22 for roughening the skeleton. The roughening mechanism 2 loosens the pre-compressed skeleton and the back of the impact surface, keeping the surface uneven. This allows the new material and recycled material to mix and interlock during the subsequent pressing process, thereby enhancing the pressing strength.

[0046] In detail, because the surfaces of the skeleton and impact surface are relatively dense and smooth after pre-compression, they are not easy to bond with the recycled material filler in the subsequent pressing steps, which can easily cause interface separation problems. Therefore, methods such as pressure rollers, scrapers, needle punching, and brushes are used to create an appropriate loose state on the back of the skeleton and impact surface, which is conducive to a tighter bond between the recycled material and the new material in the subsequent pressing steps, thereby preventing delamination.

[0047] Furthermore, such as Figure 7 As shown, the first roughening component 21 includes a placement plate 211 disposed behind the second press 12 and having a passage opening in the middle, a needle plate 212 vertically slidably connected above the placement plate 211, multiple sets of first grinding rollers 213 rotatably connected to the middle of the needle plate 212, and multiple sets of brushes 214 slidably connected around the passage opening. After the impact surface is pre-pressed, the side of the impact surface that is not impacted is needled using needle punching, and the surface is re-loosened using brush 214. The back of the impact surface and the part where it is joined with the skeleton are then rolled by rollers to make the surface uneven, which helps to improve the bonding strength in the pressing step, while the swept-out waste material forms a multi-layer buffer structure for the impact surface.

[0048] In this embodiment, after the impact surface is formed, the clamping arm 13 clamps the impact surface and places it on the placement plate 211. The needle plate 212 above moves down to needle the back of the impact surface. At the same time as the needle plate 212 moves down, the first roller 213 rolls around the contact block on the back of the impact surface to loosen the contact block. Then the needle plate 212 moves up and the brush 214 moves. The brush 214 rotates to pick up the raw material on the surface that has been loosened by the needle plate 212, achieving a looser state.

[0049] In detail, during this process, the raw materials that are picked up and fall off the contact block will remain on the back of the impact surface and be evenly distributed using the brush 214. These loose powders can be mixed with recycled materials during the pressing process to achieve a multi-layer buffer structure of "new material - new and old mixture - recycled material" on the impact surface, which enhances the bonding strength, improves the impact resistance, and avoids stress concentration.

[0050] It should be noted that the impact surface can pass through the opening. During the roughening process of the impact surface, the pressing mold 32 behind is located below the placement plate 211. The bottom of the pressing mold 32 is raised, and the impact surface is placed on top. After the roughening is completed, the bottom of the pressing mold 32 is lowered to move the impact surface into the pressing mold 32.

[0051] Furthermore, such as Figure 8 , Figure 9 , Figure 10 As shown, the second roughening component 22 includes a clamping member 221 slidably connected above the first roughening component 21, a roughening member 222 disposed on the moving path of the clamping member 221, and an adhesive attachment 223; The clamping member 221 includes a slide table 2211 slidably connected above the first roughening component 21, a fixing frame 2212 rotatably connected to the slide table 2211, a plurality of support rods 2213 rotatably connected to the bottom end of the fixing frame 2212, a plurality of clamping rods 2214 slidably connected to both sides of the fixing frame 2212, and a pressure rod 2215 rotatably connected to the upper end of the clamping rods 2214.

[0052] Furthermore, such as Figure 10 As shown, the roughening component 222 includes a splash guard 2221 disposed above the slide table 2211, a collection trough 2222 disposed below the splash guard 2221, a central roughening frame 2223 slidably connected to the middle of the splash guard 2221, multiple sets of second rollers 2224 rotatably connected to the lower part of the central roughening frame 2223, a crushing plate 2225 rotatably connected to the upper end of the central roughening frame 2223, two sets of edge roughening frames 2226 slidably connected to both ends of the central roughening frame 2223, and a crushing blade 2227 slidably connected to the edge roughening frame 2226.

[0053] Furthermore, such as Figure 11 As shown, the adhesive attachment 223 is located behind the roughening part 222 and includes a discharge port 2231 located on top of the splash guard 2221 and a nozzle 2232 located below the discharge port 2231 and located on the collection tank 2222. The pre-compressed skeleton is moved, and each surface of the skeleton is roughened. The falling waste material is collected, and then a binder is used to adhere large aggregate particles to the surface of the skeleton. This allows the recycled fine material to be embedded in the middle of the large particles in the subsequent pressing step. The surface of the new material skeleton and the recycled material achieve a tenon-and-mortise interlocking effect, which enhances the bonding strength.

[0054] In this embodiment, the clamping arm 13 places the pre-compressed skeleton onto the clamping member 221. The support rod 2213 of the clamping member 221 is located at the bottom of the skeleton, the clamping rod 2214 is located on both sides of the skeleton, and the pressure rod 2215 is located above the skeleton, thereby fixing the skeleton and preventing it from sliding. At the same time, the fixing frame 2212 rotates so that the skeleton can rotate on the slide table 2211, thereby loosening the surface and adhering coarse particles in one go.

[0055] In detail, the slide table 2211 moves the frame between the splash guard 2221 and the collection trough 2222. The central roughening frame 2223 moves down to loosen the vertical end surface in the middle of the frame. The second grinding roller 2224 moves down to loosen the sides. The crushing plate 2225 rotates to loosen the top. The edge roughening frames 2226 on both sides move down, working in conjunction with the pulverizing blade 2227 to move back and forth, thus loosening each surface of the horizontal end of the frame. Each time a surface is loosened, the frame is rotated by the rotation of the fixed frame 2212, thereby adjusting the surface to be loosened.

[0056] After surface treatment, the skeleton moves below the discharge port 2231, which outputs coarse particles downwards. The nozzle 2232 sprays binder upwards in a mist form, which adheres to the surface of the skeleton. The skeleton continues to rotate. During this process, the coarse particles are adhered to the surface of the skeleton by the binder. In this way, the binder can be sprayed more evenly on the surface of the skeleton, so that the coarse particles can also adhere to the skeleton more evenly.

[0057] It should be noted that after the coarse particles adhere to the surface of the skeleton, the grooves formed by the roughening of the surface increase the contact area between the recycled material and the skeleton. At the same time, the recycled material is mainly fine powder. During the pressing process, the fine powder enters the middle of the coarse particles. After pressing, a mutually interlocking structure of recycled material and fine material is formed, and the skeleton and recycled material interlock, achieving a better bonding effect.

[0058] It is worth mentioning that the loose waste and coarse particles generated during the surface treatment of the skeleton fall into the collection tank 2222. After being mixed with the binder, they have strong bonding properties and can be transferred to the subsequent pressing step as part of the filler, thereby improving the utilization rate of raw materials and avoiding waste.

[0059] Furthermore, such as Figure 12As shown, the pressing mechanism 3 applied in step four is located below the pre-pressing mechanism 1 and the roughening mechanism 2, and includes a pressing machine 31, a pressing mold 32 slidably connected to the pressing machine 31, and a filling component 33 located behind the roughening mechanism 2.

[0060] The filling component 33 includes a surrounding plate 331 placed on the moving path of the pressing mold 32, grippers 332 slidably connected to both sides of the surrounding plate 331, a drill bit 333 slidably connected to one side of the surrounding plate 331, a block 334 slidably connected to the other side of the surrounding plate 331, a discharge pipe 335 placed above the surrounding plate 331, and a recovery pipe 336 communicating with the collection trough 2222; The pressing mechanism 3 transfers the skeleton to the pressing mold 32 and drills holes at the joint position between the skeleton and the impact surface. It releases some recycled material into the enclosure plate 331 and mixes this recycled material with the scattered new material on the impact surface to form a mixed buffer layer. Then, a large amount of recycled material is released to fill the skeleton and squeezed into the drilled holes to form a tenon-and-mortise connection between the skeleton, the recycled material filler and the impact surface, and then proceeds to complete the pressing and molding process.

[0061] In this embodiment, a movable pressing mold 32 is provided. It first stays below the placement plate 211 so that the impact surface can be directly placed on the pressing mold 32 for surface roughening. Then it moves below the filling component 33 to perform the splicing of the skeleton and the impact surface and the filling of recycled material.

[0062] In detail, the gripper 332 moves the skeleton from the slide table 2211 to the impact surface. The drill bit 333 drills holes in the contact block of the impact surface and the end of the skeleton. The discharge pipe 335 releases some recycled material, while the recycling pipe 336 releases the waste material from the collection tank 2222. The two mix and spread on the back of the impact surface, forming a second buffer layer with the original loose fine material. Then, recycled material is released again, and the plug is used to fill the drilled holes with recycled material, so that the filling material formed by the recycled material interlocks with the skeleton and the impact surface. Then, the bottom of the pressing mold 32 moves down, allowing the skeleton and raw material to enter the mold. Recycled material continues to be filled. After filling, the pressing machine 31 is used to thoroughly press and shape the skeleton.

[0063] It should be noted that at this point, the back of the impact surface utilizes a mixture of new and recycled materials to form a three-layer buffer structure. Furthermore, the fibers embedded in the impact surface and the subsequent buffer layer form a microscopic mechanical interlock that crosses the bonding interface, greatly enhancing the interlayer bonding force. This effectively resists shear stress caused by differences in thermal expansion coefficients and prevents delamination.

[0064] In the description of this invention, it should be understood that the terms "front and back", "left and right", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention.

[0065] Of course, those skilled in the art should understand that the term "a" should be understood as "at least one" or "one or more". That is, in one embodiment, the number of an element can be one, while in another embodiment, the number of the element can be multiple. The term "a" should not be understood as a limitation on the quantity.

[0066] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art under the technical guidance of the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A preparation process for high-temperature flexural strength magnesia-carbon bricks, characterized in that, include: Step one, the recycling step, involves recycling waste magnesia-carbon bricks to form recycled materials; Step 2, Pre-compression step: Use new materials to pre-compress into skeleton and impact surface, and add fibers during the pressing of impact surface to seal the pores on impact surface and enhance impact surface strength. Step 3, roughening step, uses methods such as pressure rollers, scrapers, needle punching, and brushes to roughen the surface of the pre-pressed skeleton and the pressing surface of the impact surface, making the pressing surface rough and uneven, while adhering large particles of new material to the surface of the skeleton. Step four, the pressing step, combines the skeleton with the impact surface, and simultaneously opens holes in the skeleton and the impact surface. The mortise and tenon structure is used to enhance the bonding strength. It is then moved into the mold, and the empty parts are filled with recycled material, so that the impact surface presents a multi-layer buffer structure of "new material - new and old mixture - recycled material".

2. The preparation process of a high-temperature flexural strength magnesia-carbon brick according to claim 1, comprising a waste recycling device applied in step one, characterized in that, It also includes a pre-compression mechanism applied to step two. The pre-compression mechanism is located behind the waste recycling equipment and includes a first press for pre-compressing the skeleton, a second press for pre-compressing the impact surface, a clamping arm for clamping the skeleton and the impact surface, and a pre-compression assembly set on the second press for adding fibers to the impact surface. The first press and the second press are equipped with pre-press molds for pressing out the skeleton and the impact surface into corresponding shapes, respectively, and the pressing blocks of the molds are equipped with negative pressure devices. The first and second presses pre-press the magnesia-carbon brick skeleton and impact surface using new materials. While pressing the impact surface, negative pressure is used to assist the discharge of internal gas and simultaneously adsorb the fibers into the pores formed by the gas discharge, thereby sealing the pores. At the same time, the fibers form anchors to strengthen the bonding strength between the impact surface and the material behind it.

3. The preparation process of a high-temperature flexural strength magnesia-carbon brick according to claim 2, characterized in that, The pre-compression assembly includes a perforated plate with a square hole in the middle, which is disposed on the pre-compression mold; two sets of partitions slidably connected below the perforated plate; a fiberboard with the same square hole in the middle, which is disposed below the partitions; air jets on both sides of the fiberboard; a cover plate slidably connected to the bottom of the fiberboard; a supplementary cavity slidably connected to the bottom of the fiberboard; and a pressure plate disposed at the bottom of the supplementary cavity. New material is filled into the pre-compression mold, and then a pre-compression is performed to expel a large amount of air from the new material, forming pores. At this time, the fiber is still in a fluffy state. Then, negative pressure is used to adsorb the fiber into the pores, and the remaining raw material is added for a second extrusion to complete the initial forming of the impact surface. This achieves the filling of pores on the impact surface by the fiber and enhances the structural strength.

4. The preparation process of a high-temperature flexural strength magnesia-carbon brick according to claim 2, characterized in that, It also includes a roughening mechanism applied to step three. The roughening mechanism is located behind the pre-compression mechanism and performs different roughening treatments on the skeleton and the impact surface, including a first roughening component for roughening the impact surface and a second roughening component for roughening the skeleton. The roughening mechanism loosens the pre-compressed skeleton and the back of the impact surface, keeping the surface uneven. This allows the new and recycled materials to mix and interlock during the subsequent pressing process, thus enhancing the pressing strength.

5. The preparation process of a high-temperature flexural strength magnesia-carbon brick according to claim 4, characterized in that, The first roughening component includes a placement plate disposed behind the second press and having a passage opening in the middle, a needle plate vertically and slidably connected above the placement plate, multiple sets of first grinding rollers rotatably connected to the middle of the needle plate, and multiple sets of brushes slidably connected around the passage opening. After the impact surface is pre-pressed, the side of the impact surface that is not impacted is needled using a needle punch, and the surface is loosened again using a brush. The back of the impact surface and the part where it meets the skeleton are then rolled by a roller to make the surface uneven. This helps to improve the bonding strength during the pressing process, while the swept-out waste material forms a multi-layer buffer structure for the impact surface.

6. The preparation process of a high-temperature flexural strength magnesia-carbon brick according to claim 5, characterized in that, The second roughening component includes a clamping member slidably connected above the first roughening component, a roughening member disposed on the moving path of the clamping member, and an adhesive attachment; The clamping component includes a slide table slidably connected above the first roughening component, a fixed frame rotatably connected to the slide table, a plurality of support rods rotatably connected to the bottom end of the fixed frame, a plurality of clamping rods slidably connected to both sides of the fixed frame, and a pressure rod rotatably connected to the upper end of the clamping rods.

7. The preparation process of a high-temperature flexural strength magnesia-carbon brick according to claim 6, characterized in that, The roughening component includes a splash guard disposed above the slide table, a collection trough disposed below the splash guard, a central roughening frame slidably connected in the middle of the splash guard, multiple sets of second grinding rollers rotatably connected to the lower part of the central roughening frame, a crushing plate rotatably connected to the upper end of the central roughening frame, two sets of edge roughening frames slidably connected to both ends of the central roughening frame, and a crushing blade slidably connected to the edge roughening frame.

8. The preparation process of a high-temperature flexural strength magnesia-carbon brick according to claim 7, characterized in that, The adhesive attachment is located behind the roughening part and includes a discharge port located on top of the splash guard and a nozzle located below the discharge port and on the collection tank. The pre-compressed skeleton is moved, and each surface of the skeleton is roughened. The falling waste material is collected, and then a binder is used to adhere large aggregate particles to the surface of the skeleton. This allows the recycled fine material to be embedded in the middle of the large particles in the subsequent pressing step. The surface of the new material skeleton and the recycled material achieve a tenon-and-mortise interlocking effect, which enhances the bonding strength.

9. The preparation process of a high-temperature flexural strength magnesia-carbon brick according to claim 4, characterized in that, It also includes a pressing mechanism applied to step four. The pressing mechanism is located below the pre-pressing mechanism and the roughening mechanism, and includes a pressing machine, a pressing mold slidably connected to the pressing machine, and a filling component located behind the roughening mechanism.

10. The preparation process of a high-temperature flexural strength magnesia-carbon brick according to claim 9, characterized in that, The filling assembly includes a side plate placed on the moving path of the pressing mold, grippers slidably connected to both sides of the side plate, a drill bit slidably connected to one side of the side plate, a block slidably connected to the other side of the side plate, a discharge pipe placed above the side plate, and a recovery pipe connected to the collection trough. The pressing mechanism transfers the skeleton to the pressing mold and drills holes at the joint between the skeleton and the impact surface. It releases some recycled material into the enclosure and mixes this recycled material with the scattered new material on the impact surface to form a mixed buffer layer. Then, a large amount of recycled material is released to fill the skeleton and squeezed into the drilled holes to form a tenon-and-mortise connection between the skeleton, the recycled material filler and the impact surface, and then proceeds to complete the pressing and molding process.

Images