A process for the production of clay bricks

Abstract

This application relates to the field of clay brick blank production technology and discloses a clay brick blank production process. The clay raw material processing method involves selecting clay with a plasticity index between 15 and 25 as the main raw material. The clay is crushed, ground, and passed through an 80-100 mesh sieve to remove impurities. An appropriate amount of water is added, and the mixture is stirred in a mixer to prepare a clay slurry with a moisture content of 20%-25%. The stirring speed is controlled at 300-400 r / min, and the stirring time is 15-20 minutes to ensure the clay slurry... The material exhibits uniform texture. The foam addition process of this invention precisely controls the foam generation parameters and mixing method, ensuring the foam is uniformly dispersed in the clay slurry. This results in a uniform, fine, and stable pore structure within the clay brick blank, effectively reducing the density of the clay brick to 0.8-1.2 g / cm³. Simultaneously, it improves the brick's thermal insulation performance, reducing the thermal conductivity to 0.2-0.4 W / (m·K), and the compressive strength of the brick blank can reach 3-8 MPa, meeting the requirements for building applications.

Description

Technical Field

[0001] This application relates to the technical field of clay brick blank production, and in particular to a clay brick blank production process. Background Technology

[0002] Clay bricks, as a traditional building material, have long held an important position in the construction industry due to their advantages such as convenient sourcing, low cost, and stable performance. However, traditional clay bricks have problems such as heavy weight, high thermal conductivity, and high energy consumption. With the increasing requirements for building energy conservation and green building materials, the development of clay bricks with long holes, heat insulation, and energy saving has become an urgent need for the industry.

[0003] Adding foam to the raw material of clay bricks is an effective way to prepare clay bricks with long holes. By introducing a large number of evenly distributed pores into the clay matrix, the density of the bricks can be significantly reduced and the thermal insulation performance can be improved.

[0004] However, in practical applications, most existing foam addition processes suffer from problems such as uneven mixing of foam and clay slurry, easy foam breakage, and disordered pore distribution. These issues result in insufficient strength and unstable thermal insulation performance of the produced clay brick blanks, which seriously affect the product quality and production efficiency of long-hole clay bricks.

[0005] Therefore, those skilled in the art provide a process for producing clay brick blanks to solve the problems mentioned in the background art. Summary of the Invention

[0006] To address the problems in the foam addition process mentioned above, such as uneven mixing of foam and clay slurry, easy foam breakage, and disordered pore distribution, which lead to insufficient strength and unstable thermal insulation performance of the resulting clay brick blanks and seriously affect the product quality and production efficiency of long-hole clay bricks, this application provides a clay brick blank production process.

[0007] The clay brick blank production process provided in this application adopts the following technical solution, including the following steps:

[0008] Step 1: Raw material selection;

[0009] Step 2: Foam formation;

[0010] Step 3: Adding and mixing foam;

[0011] Step 4: Brick blank forming;

[0012] Step 5: Drying process.

[0013] Preferred raw material selection includes:

[0014] Clay raw material processing: Select clay with a plasticity index between 15 and 25 as the main raw material. Crush and grind the clay, pass it through an 80-100 mesh sieve to remove impurities, add an appropriate amount of water, and stir it in a mixer to prepare a clay slurry with a moisture content of 20%-25%. The stirring speed is controlled at 300-400 r / min, and the stirring time is 15-20 minutes to ensure that the clay slurry has a uniform texture and no obvious particle lumps.

[0015] Preparation of foam particles: Select animal protein foam particles or plant protein foam particles. Dilute the foam particles with water at a mass ratio of 1:30 to 1:50. After stirring evenly, obtain an aqueous solution of foam particles. Stir at a speed of 200-300 r / min for 5-10 minutes to ensure complete dissolution of the foam particles.

[0016] Preferably, foam generation involves adding the prepared aqueous solution of foam particles to a foam generator, adjusting the inlet pressure of the foam generator to 0.2-0.4 MPa, and the stirring speed to 800-1000 r / min, generating foam through mechanical stirring and mixing with the gas. The generated foam should have uniform pore size, controlled between 0.5-2 mm, a density of 0.05-0.1 g / cm³, and good stability, with a volume loss rate not exceeding 10% after standing for 30 minutes.

[0017] Preferred: Foam addition and mixing includes:

[0018] Quantitative addition of foam: Calculate the required amount of foam to be added based on the density requirements of the long-hole clay bricks. Typically, the volume of foam accounts for 30% - 60% of the total volume of the clay slurry and foam.

[0019] Low-speed mixing: After adding the foam to the clay slurry, reduce the mixer speed to 100-150 r / min and mix at a low speed for 10-15 minutes. Use a paddle mixer with curved blades to reduce shear force on the foam during mixing, preventing foam breakage and ensuring the foam is evenly dispersed in the clay slurry, forming a foam-clay composite slurry mixture.

[0020] Preferred method: Brick blank forming involves injecting a uniformly mixed foam-clay composite slurry into a brick blank mold, and then pressing it into shape using a vibration frequency of 50-60Hz, an amplitude of 0.5-1mm, and a vibration time of 1-2 minutes. This ensures that the composite slurry is evenly distributed in the mold, removes air bubbles, and guarantees the density of the brick blank. After forming, the brick blank is left to cure in the mold for 2-4 hours until it has initially hardened before demolding.

[0021] Preferred method: The drying process includes placing the demolded brick blanks in a drying chamber for drying. The temperature of the drying chamber is controlled at 10-30℃, the relative humidity at 40%-60%, and the drying time is 30-60 hours, reducing the moisture content of the brick blanks to below 10%. A gradual heating method is used during the drying process to avoid sudden temperature increases that could cause cracks in the brick blanks. The dried brick blanks can then be fired as needed at a firing temperature of 900-1100℃ for forty days, ultimately producing the finished elongated porous clay brick.

[0022] In summary, this application includes the following beneficial technical effects:

[0023] 1. The foam particles of the present invention, through precise control of foam generation parameters and addition mixing method, enable foam to be uniformly dispersed in clay slurry, forming a uniform, fine and stable pore structure in the clay brick blank, effectively reducing the density of clay brick, while improving the thermal insulation performance of brick, reducing the thermal conductivity to 0.2-0.4 W / (m・K), and effectively improving the compressive strength of brick blank, while also improving the ability to expand and contract with heat.

[0024] 2. While ensuring product performance, the simplified process steps and efficient mixing methods shorten the production cycle, improve production efficiency, and reduce production energy consumption.

[0025] 3. The process steps of this invention are clear, and the equipment used are all conventional building material production equipment, requiring no large-scale equipment modification, making it easy for enterprises to produce, apply, and promote. The process involves precise control of the addition and mixing parameters of foam particles, resulting in low operational difficulty and easy automation. Detailed Implementation

[0026] 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.

[0027] This application discloses a brick blank production process for clay bricks, including the following steps:

[0028] Step 1: Raw material selection;

[0029] Step 2: Foam formation;

[0030] Step 3: Adding and mixing foam;

[0031] Step 4: Brick blank forming;

[0032] Step 5: Drying process.

[0033] In this application, the selection of raw materials includes:

[0034] Clay raw material processing: Select clay with a plasticity index between 15 and 25 as the main raw material. Crush and grind the clay, pass it through an 80-100 mesh sieve to remove impurities, add an appropriate amount of water, and stir it in a mixer to prepare a clay slurry with a moisture content of 20%-25%. The stirring speed is controlled at 300-400 r / min, and the stirring time is 15-20 minutes to ensure that the clay slurry has a uniform texture and no obvious particle lumps.

[0035] Preparation of foam particles: Select animal protein foam particles or plant protein foam particles. Dilute the foam particles with water at a mass ratio of 1:30 to 1:50. After stirring evenly, obtain an aqueous solution of foam particles. Stir at a speed of 200-300 r / min for 5-10 minutes to ensure complete dissolution of the foam particles.

[0036] In this application, foam generation includes adding a prepared aqueous solution of foam particles to a foam generator, adjusting the inlet pressure of the foam generator to 0.2-0.4 MPa, and the stirring speed to 800-1000 r / min, generating foam through mechanical stirring and mixing with gas. The generated foam should have uniform pore size, controlled between 0.5-2 mm, a density of 0.05-0.1 g / cm³, and good stability, with a volume loss rate not exceeding 10% after standing for 30 minutes.

[0037] In this application, foam addition and mixing include:

[0038] Quantitative addition of foam: Calculate the required amount of foam to be added based on the density requirements of the long-hole clay bricks. Typically, the volume of foam accounts for 30% - 60% of the total volume of the clay slurry and foam.

[0039] Low-speed mixing: After adding the foam to the clay slurry, reduce the mixer speed to 100-150 r / min and mix at a low speed for 10-15 minutes. Use a paddle mixer with curved blades to reduce shear force on the foam during mixing, preventing foam breakage and ensuring the foam is evenly dispersed in the clay slurry, forming a foam-clay composite slurry mixture.

[0040] In this application, brick blank forming includes injecting a uniformly mixed foam-clay composite slurry into a brick blank mold, and then using a pressing method with a vibration frequency of 50-60Hz, an amplitude of 0.5-1mm, and a vibration time of 1-2 minutes to ensure that the composite slurry is evenly distributed in the mold, expelling air bubbles and ensuring the density of the brick blank. After forming, the brick blank is left to cure in the mold for 2-4 hours until it has initially hardened before demolding.

[0041] In this application, the drying process includes placing the demolded brick blanks in a drying chamber for drying. The temperature of the drying chamber is controlled at 10-30℃, the relative humidity at 40%-60%, and the drying time is 30-60 hours, reducing the moisture content of the brick blanks to below 10%. A gradual heating method is used during the drying process to avoid sudden temperature increases that could cause cracks in the brick blanks. The dried brick blanks can then be fired as needed at a firing temperature of 900-1100℃ for forty days, ultimately producing elongated porous clay bricks.

[0042] All standard parts used in this invention can be purchased from the market, and irregular parts can be customized according to the description in the specification. The specific connection methods of each part adopt conventional methods such as bolts, rivets, and welding that are mature in the prior art. The machinery, parts and equipment adopt conventional models in the prior art, and the circuit connection adopts conventional connection methods in the prior art, which will not be described in detail here.

[0043] Finally, the following points should be noted: First, in the description of this application, it should be noted that, unless otherwise specified and limited, the terms "installation", "connection", and "linkage" should be interpreted broadly, and can be mechanical or electrical connections, or internal connections between two components, or direct connections. "Up", "down", "left", "right", etc. are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may change.

[0044] Secondly: In the embodiments disclosed in this invention, only the structures involved in the embodiments disclosed in this invention are involved. Other structures can refer to the general design. In the absence of conflict, the same embodiment and different embodiments of this invention can be combined with each other.

Claims

1. A process for producing clay brick blanks, characterized in that, Includes the following steps: Step 1: Raw material selection; Step 2: Foam formation; Step 3: Adding and mixing foam; Step 4: Brick blank forming; Step 5: Drying process.

2. The brick blank production process for clay bricks according to claim 1, characterized in that: The selection of raw materials includes: Clay raw material processing: Select clay with a plasticity index between 15 and 25 as the main raw material. Crush and grind the clay, pass it through an 80-100 mesh sieve to remove impurities, add an appropriate amount of water, and stir it in a mixer to prepare a clay slurry with a moisture content of 20%-25%. The stirring speed is controlled at 300-400 r / min, and the stirring time is 15-20 minutes to ensure that the clay slurry has a uniform texture and no obvious particle lumps.

3. Preparation of foam particles: Select animal protein foam particles or plant protein foam particles, dilute the foam particles with water at a mass ratio of 1:30 to 1:50, stir evenly to obtain a foam particle aqueous solution, stir at a speed of 200-300 r / min for 5-10 minutes to fully dissolve the foam particles.

4. The brick blank production process for clay bricks according to claim 1, characterized in that: The foam generation process involves adding the prepared aqueous solution of foam particles into a foam generator, adjusting the inlet pressure of the foam generator to 0.2-0.4 MPa, and the stirring speed to 800-1000 r / min, generating foam through mechanical stirring and mixing with the gas. The generated foam should have uniform pore size, controlled between 0.5-2 mm, a density of 0.05-0.1 g / cm³, and good stability, with a volume loss rate not exceeding 10% after standing for 30 minutes.

5. The brick blank production process for clay bricks according to claim 1, characterized in that: The foam addition and mixing include: Quantitative addition of foam: Calculate the required amount of foam to be added based on the density requirements of the long-hole clay bricks. Typically, the volume of foam accounts for 30% - 60% of the total volume of the clay slurry and foam. Low-speed mixing: After adding the foam to the clay slurry, reduce the mixer speed to 100-150 r / min and mix at a low speed for 10-15 minutes. Use a paddle mixer with curved blades to reduce shear force on the foam during mixing, preventing foam breakage and ensuring the foam is evenly dispersed in the clay slurry, forming a foam-clay composite slurry mixture.

6. The brick blank production process for clay bricks according to claim 1, characterized in that: The brick blank forming process involves injecting a uniformly mixed foam-clay composite slurry into a brick blank mold, and then pressing it into shape using a vibration frequency of 50-60Hz, an amplitude of 0.5-1mm, and a vibration time of 1-2 minutes. This ensures that the composite slurry is evenly distributed in the mold, removes air bubbles, and guarantees the density of the brick blank. After forming, the brick blank is left to cure in the mold for 2-4 hours until it has initially hardened before being demolded.

7. The brick blank production process for clay bricks according to claim 1, characterized in that: The drying process involves placing the demolded brick blanks in a drying chamber at a controlled temperature of 10-30℃ and a relative humidity of 40%-60% for 30-60 hours, reducing the moisture content of the brick blanks to below 10%. A gradual temperature increase is used during drying to prevent sudden temperature rises that could cause cracks in the brick blanks. The dried brick blanks can then be fired as needed at a temperature of 900-1100℃ for forty days, ultimately producing elongated, porous clay bricks.