Process for the production of autoclaved aerated concrete profiles

Abstract

The application discloses a production process of autoclaved aerated concrete special-shaped piece, and the special-shaped movable die is adjusted from an initial position to a working position when pouring is needed, and then the two special-shaped movable dies and the two fixed dies are clamped by fixed screws and nuts, at the moment, the two special-shaped movable dies and the two fixed dies are clamped to form a pouring cavity, and concrete is poured into the pouring cavity, and at the same time, a vibrating motor is started to vibrate the vibrating plate, the vibrating plate starts to vibrate under the action of the vibrating motor and the spring, the raw materials are more full in the mold, and residual gaps in the finished product caused by residual gas in the raw materials are avoided to affect the quality; after pouring is completed, the raw materials are shaped, the fixed screws and nuts are disassembled after shaping is completed, and then the poured concrete special-shaped piece is pushed out and collected, and the autoclaved aerated concrete obtained through the step S1 has more optimal raw material feeding ratio, the bonding strength between components of the autoclaved aerated concrete is improved, the mechanical strength of the product is improved, and the service life of the product is prolonged.

Description

Technical Field

[0001] This invention relates to the field of concrete irregular part processing technology, specifically a production process for autoclaved aerated concrete irregular parts. Background Technology

[0002] Autoclaved aerated concrete (AAC) blocks are porous concrete products made from fly ash, lime, cement, gypsum, slag, and other main raw materials, with the addition of appropriate amounts of foaming agents, regulators, and bubble stabilizers. They are produced through processes such as batching and mixing, pouring, static curing, cutting, and high-pressure autoclaving. Their performance is superior to ordinary adhesive bricks in terms of weight, strength, thermal insulation, and sound insulation, making them a common building material in construction.

[0003] Existing autoclaved aerated concrete (AAC) blocks suffer from low bond strength between components, resulting in low mechanical strength and a short service life. Furthermore, air bubbles can easily form within the blocks during production, further impacting their lifespan. Therefore, this invention proposes a manufacturing process for irregularly shaped AAC blocks to address these issues. Summary of the Invention

[0004] The purpose of this invention is to provide a production process for autoclaved aerated concrete (AAC) irregular-shaped parts, aiming to solve the problems raised in the background art.

[0005] This invention is achieved through the following technical solution:

[0006] This invention relates to a manufacturing process for autoclaved aerated concrete (AAC) irregular-shaped parts, comprising the following steps:

[0007] S1: Preparation of autoclaved aerated concrete: Mixture 1 is made by mixing mullite powder, calcium hydroxide powder and water in a ratio of 25:12:63. Mixture 2 is made by mixing river sand and talc powder in a ratio of 67:33. Mixture 1 and Mixture 2 are then mixed and stirred and allowed to stand for 120-140 minutes to obtain Mixture 3. Mixture 3 is then transferred to an autoclave, vacuumed to between -0.07MPa and -0.05MPa, and then steam is injected to 200℃ for autoclaving and curing for 7-9 hours to obtain autoclaved aerated concrete.

[0008] S2: Mold Adjustment: The mold includes a base and a mold assembly. The base includes a base plate and a vibrating plate. A spring is provided between the base plate and the vibrating plate. The vibrating plate is connected to a vibration motor. The mold assembly includes two irregularly shaped moving molds and two fixed molds. The fixed molds are located on the top surface of the base. The base is fixedly located on the top surface of the vibrating plate. The vibrating plate is also provided with a fixed seat. The irregularly shaped moving molds are hinged to the fixed seats. The irregularly shaped moving molds are provided with fixed ears. The fixed ears are provided with through holes. A fixed screw is provided between the two through holes. The fixed screw is fixedly connected to the two fixed ears by nuts. After the two irregularly shaped moving molds and the two fixed molds are closed, a casting cavity is formed.

[0009] S3: Pouring. The autoclaved aerated concrete obtained in step S1 is slowly poured into the pouring cavity formed after the mold is closed in step S2. At the same time, the vibration motor is started to vibrate, which in turn drives the vibration plate to vibrate. At this time, while the autoclaved aerated concrete is poured into the pouring cavity, the autoclaved aerated concrete inside the pouring cavity will be shaken. During the shaking process, the formed air pores are compressed and the air is expelled, resulting in concrete blocks without air pores and holes.

[0010] S4: Natural cooling and molding. After pouring, the concrete blocks will naturally cool for 2-3 days and then naturally mold.

[0011] S5: Disassembly and unloading. After removing the fixing screw from the fixing lug, separate the irregular moving mold and the fixed mold. At this time, the left and right sides of the irregular concrete block are exposed. Push the concrete block from one side to unload the concrete block and obtain the irregular concrete part.

[0012] Preferably, the surface of the irregularly shaped moving mold located in the mold cavity in step S2 is an irregularly shaped surface, which changes by replacing the irregularly shaped moving mold.

[0013] Preferably, in step S4, the concrete blocks are cooled by heating, and the concrete blocks are placed in a heater chamber at a temperature of 40-60°C for 1-2 days to accelerate the molding process.

[0014] Preferably, a robotic arm is used to grip the material during unloading in step S5.

[0015] Compared with the prior art, the present invention has the following beneficial effects:

[0016] When pouring is required, the irregularly shaped moving mold is manually or electrically adjusted from its initial position to its working position. Then, the fixing screw is passed through two corresponding through holes, and nuts are tightened at both ends of the fixing screw. The nuts are used to close the two irregularly shaped moving molds and two fixed molds, forming a pouring cavity. Concrete is poured into the pouring cavity, and at the same time, the vibration motor is started to vibrate the vibrating plate. Under the action of the vibration motor and spring, the vibrating plate begins to vibrate, so that the raw material is more fully packed in the mold, avoiding residual gas in the raw material from causing residual gaps in the finished product and affecting the quality. After pouring, the raw material is shaped. After shaping, the fixing screw and nuts are removed, and then the irregularly shaped moving mold is adjusted from the working position to the initial position. The poured concrete irregularly shaped part is then pushed out and collected. The autoclaved aerated concrete obtained through step S1 uses a better raw material feeding ratio, which helps to improve the bonding strength between the components of autoclaved aerated concrete, better improve the mechanical strength of the product, help extend the service life of the product, and facilitate the market promotion of the product. Attached Figure Description

[0017] Figure 1 This is a perspective view of the overall structure of the present invention;

[0018] Figure 2 This is a front view of the overall structure of the present invention during casting;

[0019] Figure 3 This is a front view of the overall structure of the present invention during material cutting;

[0020] Figure 4 This is a top view of the overall structure of the present invention during material cutting.

[0021] In the diagram: 1. Base; 11. Base plate; 12. Vibrating plate; 13. Spring;

[0022] 2. Mold assembly; 21. Irregular moving mold; 22. Fixed mold; 23. Fixed lug; 24. Through hole; 25. Fixed screw; 26. Nut; 27. Fixed seat; 28. Base. Detailed Implementation

[0023] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0024] The components of the embodiments of the invention described and shown in the accompanying drawings can typically be arranged and designed in a variety of different configurations. Therefore, the following detailed description of the embodiments of the invention provided in the drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention.

[0025] Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element 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. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0027] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0028] Please see Figures 1 to 4 This invention provides a technical solution: a production process for autoclaved aerated concrete (AAC) irregular-shaped parts, comprising the following steps:

[0029] S1: Preparation of autoclaved aerated concrete: Mixture 1 is made by mixing mullite powder, calcium hydroxide powder and water in a ratio of 25:12:63. Mixture 2 is made by mixing river sand and talc powder in a ratio of 67:33. Mixture 1 and Mixture 2 are then mixed and stirred and allowed to stand for 120-140 minutes to obtain Mixture 3. Mixture 3 is then transferred to an autoclave, vacuumed to between -0.07MPa and -0.05MPa, and then steam is injected to 200℃ for autoclaving and curing for 7-9 hours to obtain autoclaved aerated concrete.

[0030] S2: Mold debugging: The mold includes a base 1 and a mold assembly 2. The base 1 includes a base plate 11 and a vibrating plate 12. A spring 13 is provided between the base plate 11 and the vibrating plate 12. The vibrating plate 12 is connected to a vibration motor. The mold assembly 2 includes two irregularly shaped moving molds 21 and two fixed molds 22. The fixed molds 22 are located on the top surface of the base 28. The base 28 is fixedly located on the top surface of the vibrating plate 12. The vibrating plate 12 is also provided with a fixed seat 27. The irregularly shaped moving molds 21 are hinged to the fixed seat 27. The irregularly shaped moving molds 21 are provided with fixed ears 23. The fixed ears 23 are provided with through holes 24. A fixing screw 25 is provided between the two through holes 24. The fixing screw 25 is fixedly connected to the two fixed ears 23 by nuts 26. After the two irregularly shaped moving molds 21 and the two fixed molds 22 are closed, a casting cavity is formed.

[0031] S3: Pouring. The autoclaved aerated concrete obtained in step S1 is slowly poured into the pouring cavity formed after the mold is closed in step S2. At the same time, the vibration motor is started to vibrate, which in turn drives the vibration plate 12 to vibrate. At this time, while the autoclaved aerated concrete is poured into the pouring cavity, the autoclaved aerated concrete inside the pouring cavity will be shaken. During the shaking process, the air pores formed are compressed and the air is expelled, resulting in concrete blocks without air pores and holes.

[0032] S4: Natural cooling and molding. After pouring, the concrete blocks will naturally cool for 2-3 days and then naturally mold.

[0033] S5: Disassembly and unloading. After removing the fixing screw 25 from the fixing ear 23, separate the irregular moving mold 21 and the fixed mold 22. At this time, the left and right sides of the irregular concrete block are exposed. Push the concrete block from one side to unload the concrete block and obtain the irregular concrete part.

[0034] In this embodiment, the rotation of the irregular moving mold 21 can be achieved by manual operation or by motor rotation. When operated electrically, the output end of the motor is fixedly connected to the rotating shaft, the rotating shaft is rotatably connected to the fixed base 27 and fixedly connected to the irregular moving mold 21. At this time, the motor can realize the mold closing and opening of the irregular moving mold 21. The motor can be programmed in advance, with the mold opening state as the initial position of the motor, and the mold closing state of the irregular moving mold 21 and the fixed mold 22 as the working position. By setting the initial position and working position data, the motor can control the movement of the irregular moving mold 21 to the initial position and working position.

[0035] When pouring is required, the irregularly shaped moving mold 21 is manually or electrically moved from its initial position (e.g., Figure 3 Adjust the position shown to the working position (e.g., the position shown). Figure 2(as shown in the image), then the fixing screw 25 passes through two corresponding through holes 24, and then nuts 26 are screwed on both ends of the fixing screw 25. The nuts 26 are used to close the two irregular moving molds 21 and the two fixed molds 22. At this time, the two irregular moving molds 21 and the two fixed molds 22 are closed to form a pouring cavity. Concrete is poured into the pouring cavity. At the same time, the vibration motor is started to vibrate the vibrating plate 12. Under the action of the vibration motor and the spring 12, the vibrating plate 12 begins to vibrate to achieve vibration during pouring, so that the raw material is more compact in the mold and avoids residual gas in the raw material causing residual gaps in the finished product, which affects the quality. After pouring, the raw material is shaped. After shaping, the fixing screw 25 and nuts 26 are removed, and then the irregular moving mold 21 is started from the working position (as shown in the image). Figure 2 Adjust the position shown to the initial position (e.g., the position shown). Figure 3 (As shown in the image), then push the completed concrete irregular-shaped part out for collection;

[0036] The autoclaved aerated concrete obtained through step S1 uses a better raw material feeding ratio, which helps to improve the bond strength between the components of the autoclaved aerated concrete, better improve the mechanical strength of the product, help extend the service life of the product, and facilitate the market promotion of the product.

[0037] For further details, please refer to Figure 3 In step S2, the irregular moving mold 21 has an irregular surface located inside the mold cavity. The irregular surface changes by replacing the irregular moving mold 21.

[0038] In this embodiment, the irregularly shaped moving mold 21 has an irregularly shaped surface inside the mold cavity. Matching patterns can be customized according to actual production needs. Different irregularly shaped parts can be manufactured by changing the irregularly shaped moving mold 21.

[0039] Furthermore, in step S4, the concrete blocks are cooled by heating, and the concrete blocks are placed in a heater chamber at a temperature of 40-60℃ for 1-2 days to accelerate the molding process.

[0040] In this embodiment, concrete blocks are placed in a heater chamber at a temperature of 40-60°C for 1-2 days to accelerate molding. The temperature of 40-60°C will not cause the concrete to crack due to rapid heating, while it can speed up the molding time and preparation speed.

[0041] Furthermore, in step S5, a robotic arm is used to grip the material during unloading.

[0042] In this embodiment, a robotic arm is used for gripping. Rubber pads should be added to the gripping surface of the robotic arm to prevent the surface of the concrete block from being damaged due to excessive force applied by the robotic arm, which would affect its use.

[0043] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A manufacturing process for autoclaved aerated concrete (AAC) irregular-shaped parts, characterized in that, Includes the following steps: S1: Preparation of autoclaved aerated concrete: Mixture 1 is made by mixing mullite powder, calcium hydroxide powder and water in a ratio of 25:12:

63. Mixture 2 is made by mixing river sand and talc powder in a ratio of 67:

33. Mixture 1 and Mixture 2 are then mixed and stirred and allowed to stand for 120-140 minutes to obtain Mixture 3. Mixture 3 is then transferred to an autoclave, vacuumed to between -0.07MPa and -0.05MPa, and then steam is injected to 200℃ for autoclaving and curing for 7-9 hours to obtain autoclaved aerated concrete. S2: Mold Adjustment: The mold includes a base (1) and a mold assembly (2). The base (1) includes a base plate (11) and a vibrating plate (12). A spring (13) is provided between the base plate (11) and the vibrating plate (12). The vibrating plate (12) is connected to a vibration motor. The mold assembly (2) includes two irregularly shaped moving molds (21) and two fixed molds (22). The fixed molds (22) are located on the top surface of the base (28). The base (28) is fixedly located on the top surface of the vibrating plate (12). The plate (12) is also provided with a fixed seat (27). The irregular moving mold (21) is hinged to the fixed seat (27). The irregular moving mold (21) is provided with a fixed ear (23). The fixed ear (23) is provided with a through hole (24). A fixed screw (25) is provided between the two through holes (24). The fixed screw (25) is fixedly connected to the two fixed ears (23) by a nut (26). After the two irregular moving molds (21) and the two fixed molds (22) are closed, a casting cavity is formed. S3: Pouring, slowly pour the autoclaved aerated concrete obtained in step S1 into the pouring cavity formed after the mold is closed in step S2, and at the same time start the vibration motor to vibrate, thereby driving the vibration plate (12) to vibrate. At this time, while pouring autoclaved aerated concrete into the pouring cavity, the autoclaved aerated concrete inside the pouring cavity will be shaken. During the shaking process, the formed air holes are compressed so that the air is expelled, and concrete blocks without air holes and pores are obtained. S4: Natural cooling and molding. After pouring, the concrete blocks will naturally cool for 2-3 days and then naturally mold. S5: Disassembly and unloading. After disassembling the fixing screw (25) from the fixing ear (23), separate the irregular moving mold (21) and the fixing mold (22). At this time, the left and right sides of the irregular concrete block are exposed. Push the concrete block from one side to unload the concrete block and obtain the concrete irregular part.

2. The production process of autoclaved aerated concrete (AAC) irregular-shaped parts according to claim 1, characterized in that: The irregular moving mold (21) in step S2 has an irregular surface on the surface inside the mold cavity, which changes by replacing the irregular moving mold (21).

3. The production process of autoclaved aerated concrete (AAC) irregular-shaped parts according to claim 1, characterized in that: In step S4, the concrete blocks are cooled by heating, and the concrete blocks are placed in a heater chamber at a temperature of 40-60℃ for 1-2 days to accelerate the molding process.

4. The production process of autoclaved aerated concrete (AAC) irregular-shaped parts according to claim 1, characterized in that: In step S5, a robotic arm is used to grip the material during unloading.

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