A lightweight refractory brick with controllable closed-pore ratio and its micropore stabilization preparation method

Abstract

This invention discloses a lightweight refractory brick with controllable closed-pore ratio and its micropore stabilization preparation method, belonging to the field of lightweight refractory brick technology. It aims to solve the technical problems of unstable pore structure and difficulty in simultaneously achieving strength and thermal insulation in refractory bricks. The brick comprises an outer ring layer, an inner ring layer, and an intermediate layer. This invention ensures the stability of the pore structure by setting an intermediate layer containing a higher content of solid combustible material between the outer and inner ring layers, and forming closed pores after sintering. This makes the refractory brick a high-performance wall material. The intermediate layer, due to its high closed-pore ratio, achieves a lower thermal conductivity and excellent thermal insulation performance. Simultaneously, the outer and inner ring layers, due to their lower closed-pore ratios, maintain high strength and erosion resistance, thus balancing the strength and thermal insulation performance of the refractory brick itself. Furthermore, the non-smooth, uneven interlocking interface between the intermediate layer, inner ring layer, and outer ring layer ensures the overall structural stability and thermal shock stability of the composite brick.

Description

Technical Field

[0001] This invention relates to the field of lightweight refractory brick technology, and more specifically, to a lightweight refractory brick with controllable closed-pore ratio and a method for preparing it with micropore stabilization. Background Technology

[0002] Lightweight refractory bricks are widely used in thermal equipment in industries such as steel, ceramics, and glass to reduce heat loss and improve thermal efficiency, making them an important lightweight building material. Traditional lightweight refractory bricks primarily introduce pores using foaming or blowing methods, which involve adding foaming agents or foam to the raw material and forming a porous structure after sintering. However, during the preparation process of these methods, gases easily escape and dissipate, resulting in uneven pore size, uncontrollable pore distribution, and poor pore structure stability, thus affecting the thermal insulation performance and service life of the refractory bricks.

[0003] Furthermore, while increasing porosity can reduce thermal conductivity, it significantly reduces brick strength, leading to insufficient resistance to erosion and corrosion. Traditional homogeneous porous structures cannot simultaneously meet the strength requirements of the inner and outer surfaces of refractory bricks in practical use; that is, the outer layer must withstand high-temperature airflow erosion and chemical corrosion, while the inner layer must maintain sufficient structural strength to resist thermal stress and mechanical loads. Currently, no technical solution exists that can simultaneously resolve the contradiction between pore structure stability, strength, and thermal insulation performance, as well as the differentiated strength requirements of the inner and outer surfaces. Therefore, we propose a lightweight refractory brick with controllable closed-pore ratio and its micropore stabilization preparation method. Summary of the Invention

[0004] The purpose of this invention is to provide a lightweight refractory brick with controllable closed-pore ratio and a method for preparing it with micropore stabilization, so as to solve the technical problems of unstable pore structure and difficulty in achieving both strength and heat insulation in refractory bricks.

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a lightweight refractory brick with controllable closed-pore ratio and a method for preparing the same by stabilizing its micropores, comprising:

[0006] The outer ring layer is formed by sintering the first mixture;

[0007] The inner ring layer is formed by sintering the first mixture;

[0008] The intermediate layer, sandwiched between the outer ring layer and the inner ring layer, is formed by sintering the second mixture;

[0009] The first mixture and the second mixture contain the same base material, and the first mixture contains a first amount of solid combustible material, the second mixture contains a second amount of solid combustible material, the second amount is greater than the first amount, and the first amount is ≥0;

[0010] Solid combustible materials burn out during sintering, forming pores in the outer ring layer, inner ring layer and middle layer respectively, so that the closed-porosity of the middle layer is greater than that of the outer ring layer and the inner ring layer.

[0011] The interfaces between the intermediate layer and the outer ring layer, as well as the interfaces between the intermediate layer and the inner ring layer, are all non-smooth, unevenly interlocked. This invention, by setting an intermediate layer containing a higher content of solid combustible material between the outer and inner ring layers, and forming closed pores after sintering, ensures the stability of the pore structure, making the refractory brick a high-performance wall material. Furthermore, the intermediate layer, due to its high closed-pore ratio, achieves a lower thermal conductivity and excellent thermal insulation performance. Simultaneously, the outer and inner ring layers, due to their lower closed-pore ratios, maintain high strength and erosion resistance, thus balancing the strength and thermal insulation performance of the refractory brick itself. In addition, the non-smooth, unevenly interlocked interfaces between the intermediate, inner, and outer ring layers significantly increase the interlayer contact area, preventing delamination and cracking caused by differences in thermal expansion coefficients, ensuring the overall structural stability and thermal shock stability of the composite brick, and solving the technical problem of unstable pore structure and difficulty in simultaneously achieving strength and thermal insulation in refractory bricks.

[0012] A method for preparing a lightweight refractory brick with controllable closed-pore ratio by stabilizing its micropores includes the following steps:

[0013] S1. Ingredients mixing;

[0014] A basic blank and a solid combustible material are provided. The solid combustible material is mixed with the basic blank in different proportions to prepare a first mixture and a second mixture, respectively.

[0015] S2, layered filling and pressing;

[0016] A layered filling method is adopted, in which the first mixture is filled into the outer mold cavity and the inner mold cavity of the refractory brick mold, and the second mixture is filled into the middle mold cavity between the outer mold cavity and the inner mold cavity, forming a composite green body composed of an outer ring layer green body, a middle layer green body and an inner ring layer green body. The composite green body is pressed to make the outer ring layer green body, the middle layer green body and the inner ring layer green body tightly bonded together.

[0017] S3, Drying;

[0018] The pressed composite green body is dried to remove free moisture;

[0019] S4, sintering;

[0020] The dried composite green body is sintered, and the solid combustible material burns away during the sintering process, forming pores in the outer ring layer, the inner ring layer and the middle layer respectively.

[0021] Preferably, in step S2, the refractory brick mold includes:

[0022] The upper mold has a square structure at the bottom with four ring-shaped protrusions.

[0023] The lower mold has a square structure at the top with four annular cavities. The protrusions are movable and fit into the annular cavities, and the bottom of the annular cavities has matching annular grooves.

[0024] Several functional modules are respectively disposed on several annular cavities, including several corner blocks A and several corner blocks B arranged in an annular and equally spaced structure. The corner blocks A and the corner blocks B have the same cross-sectional shape. Two adjacent corner blocks A are fixedly connected, so that the several corner blocks A form a closed fixed ring. The fixed ring is slidably disposed on the adapting ring groove. Two adjacent corner blocks B are slidably connected, so that the several corner blocks B form a closed movable ring. The movable ring is disposed on the annular cavity and slidably engaged with the adapting ring groove. The bottom end of the fixed ring is provided with an iris control unit for controlling the expansion and contraction of the movable ring.

[0025] The control structure is located inside the lower mold and has several lifting and rotating ends, which are respectively fixedly connected to the input ends of several iris control units.

[0026] In the initial state, the bottom end of the movable ring is flush with the bottom end of the ring cavity. The outer mold cavity is formed by the outer side of the movable ring and the outer side of the ring cavity, and the inner mold cavity is formed by the inner side of the movable ring and the inner side of the ring cavity.

[0027] After the first mixture is filled, the control structure drives the movable ring to expand and contract through the iris control unit. When the movable ring contracts, its inner surface initially compacts the first mixture in the inner mold cavity. When the movable ring expands, its outer surface initially compacts the first mixture in the outer mold cavity.

[0028] After initial compaction, the control structure drives the movable ring to return to its initial shape through the iris control unit. Then, the iris control unit drives the fixed ring and the movable ring to move until the top of the movable ring is flush with the bottom of the ring cavity, so that the gap between the initial compacted first mixture on both sides forms a central mold cavity with wavy surfaces on both sides.

[0029] Preferably, the bottom end of the adapter ring groove is connected to a ring-shaped sliding cavity, the bottom ends of the four sliding cavities are connected through mounting cavity A, a transverse groove is opened in the lower mold, the transverse groove is connected to the sliding cavity through the sliding groove, and a mounting cavity B is opened at the bottom end of the lower mold.

[0030] Preferably, the iris control unit includes a plurality of movable rods, a slip ring, a plurality of radial guide grooves, and a rotating ring. The plurality of movable rods are rotatably disposed at the bottom ends of the plurality of corner blocks B. The slip ring is slidably disposed in the sliding cavity and fixedly connected to the bottom end of the fixed ring body. A rotating groove is formed at the bottom end of the slip ring. The plurality of radial guide grooves are formed on the plurality of corner blocks A and communicate with the rotating groove. The movable rods are movably connected to the radial guide grooves. The rotating ring is rotatably disposed at the top end of the rotating groove. The top end of the rotating ring has a plurality of oblique guide grooves formed in a ring-shaped, equally spaced structure. The bottom ends of the plurality of movable rods are movably connected to the plurality of oblique guide grooves.

[0031] Preferably, the control structure includes a rotating cylinder and an annular block. The rotating cylinder is rotatably disposed on the inner surface of the sliding cavity. The surface of the rotating cylinder has a plurality of threaded grooves with an annular structure at equal intervals. The annular block is rotatably disposed at the bottom end of the rotating groove and is fixedly connected to the bottom end of the rotating ring. The inner surface of the annular block has a plurality of threaded blocks with an annular structure at equal intervals. The plurality of threaded blocks are movably connected to the plurality of threaded grooves respectively. The lifting and rotating end is composed of the annular block.

[0032] Preferably, the ring block has a movable groove, a movable block is movably connected in the movable groove, both ends of the movable groove have through grooves, the movable block and the movable groove are elastically connected by a spring, and both ends of the movable block are respectively fixed with a snap-fit ​​block A and a snap-fit ​​block B, both of which are adapted to the ring block;

[0033] The bottom surface of the slip ring is provided with a snap-fit ​​groove A that communicates with the rotating groove, and the snap-fit ​​block A extends out of the through groove and engages with the snap-fit ​​groove A;

[0034] The top of the rotating drum is provided with a snap-fit ​​groove B, and the snap-fit ​​block B extends out of the groove and engages with the snap-fit ​​groove B.

[0035] Preferably, the control structure further includes a slider and four locking sliders;

[0036] The slider is slidably disposed in the transverse groove. Four trapezoidal grooves are formed on the slider relative to the four positions of the four grooves. A trapezoidal block is movably disposed on the trapezoidal groove. A displacement guide groove is formed on the trapezoidal block. A guide block is movably connected to the displacement guide groove. The guide block is fixedly connected to the slider.

[0037] The displacement guide groove is composed of an inclined guide groove and a horizontal guide groove connected together. The inclined guide groove is opened on the inclined surface of the trapezoidal groove, and the horizontal guide groove is opened at one end of the trapezoidal block near the trapezoidal groove.

[0038] The four snap-fit ​​sliders are slidably disposed on the four slide grooves respectively. The snap-fit ​​sliders are fixedly connected to the trapezoidal grooves and snap-fit ​​with the snap-fit ​​groove A.

[0039] Preferably, one end of the slide bar has a movable circular groove, a movable shaft is movably mounted on the movable circular groove, at least one threaded guide groove is provided on the surface of the movable shaft, a ball block is movably mounted on the threaded guide groove, the ball block is rotatably connected to the movable circular groove, the movable shaft passes through the lower mold away from the movable circular groove and is fixedly mounted on a turntable, and the movable shaft is rotatably connected to the lower mold.

[0040] Preferably, the control structure further includes a motor, a central gear, a double-sided gear ring, and four side gear rings;

[0041] The motor is fixed on the mounting cavity B. The central gear and the double-sided gear ring are rotatably mounted on the mounting cavity A with an inner and outer structure. The bottom end of the central gear passes into the mounting cavity B and is fixedly connected to the output shaft of the motor. The central gear and the inner surface of the double-sided gear ring are connected by several side gears. The side gears are rotatably connected to the mounting cavity B. The four side gear rings are respectively fixed on the bottom ends of the four rotating cylinders and are connected by meshing with the outer surface of the double-sided gear ring.

[0042] The beneficial effects of this invention are:

[0043] 1. This invention establishes an intermediate layer containing a higher content of solid combustible material between the outer and inner ring layers, forming closed pores after sintering. This ensures the stability of the pore structure, making the refractory brick a high-performance wall material. The intermediate layer, due to its high closed-pore ratio, achieves a lower thermal conductivity and excellent thermal insulation performance. Meanwhile, the outer and inner ring layers, with their lower closed-pore ratios, maintain high strength and erosion resistance, thus balancing the strength and thermal insulation performance of the refractory brick itself. Furthermore, the non-smooth, uneven interlocking interface between the intermediate, inner, and outer ring layers significantly increases the interlayer contact area, preventing delamination and cracking caused by differences in thermal expansion coefficients. This ensures the overall structural stability and thermal shock stability of the composite brick, solving the technical problem of unstable pore structure and difficulty in balancing strength and thermal insulation in refractory bricks.

[0044] 2. This invention also designs the structure of the refractory brick mold so that, in the initial state, the bottom end of the movable ring is flush with the bottom end of the ring cavity. The outer surface of the movable ring and the outer side of the ring cavity form an outer mold cavity, and the inner surface of the movable ring and the inner side of the ring cavity form an inner mold cavity for filling the first mixture. After filling the first mixture, the upper mold is moved so that the top of the protrusion contacts the top of the movable ring. Rotating the ring changes the gap position of the intersecting oblique guide groove and radial guide groove, thereby causing the movable rod to move relative to the radial guide groove. This causes several corner blocks B to move synchronously, resulting in the expansion and contraction of the movable ring. When the movable ring shrinks, its inner surface initially compacts the first mixture in the inner mold cavity. When the movable ring expands, its outer surface initially compacts the first mixture in the outer mold cavity, preventing loose powder from collapsing or mixing in subsequent processes. This initial compaction prevents the loose powder from collapsing or mixing in subsequent processes. Afterwards, the movable ring is driven to return to its initial shape. Then, the iris control unit, the fixed ring, and the movable ring are moved so that the top of the movable ring is flush with the bottom of the ring cavity. This causes the gap between the first mixture on both the inner and outer sides to be initially compacted, forming a central mold cavity with wavy surfaces on both sides. After the upper mold is removed and the second mixture is filled into the central mold cavity, the upper mold is moved again, so that the protrusion is pressed into the ring cavity to perform the final overall pressing of the three-layer composite green brick. This makes the outer ring layer, the middle layer, and the inner ring layer tightly bonded, and gives the brick the final shape and density. Moreover, the expansion and contraction range of the movable ring and the amount of filling material of the first mixture can be designed according to actual needs, thereby changing the relative volume of the outer ring layer, the inner ring layer, and the middle layer. This allows for flexible adjustment of the closed-cell rate and the thickness ratio of the three layers of the refractory brick, thereby controlling the overall strength and thermal insulation performance of the brick as needed. Attached Figure Description

[0045] Figure 1 This is a schematic diagram of the structure of the refractory brick of the present invention;

[0046] Figure 2 This is a schematic diagram of the structure of the refractory brick mold of the present invention;

[0047] Figure 3 This is a cross-sectional structural diagram of the lower mold, functional modules, and control structure of the present invention.

[0048] Figure 4 This is a partial structural breakdown diagram of the lower mold and control structure of the present invention;

[0049] Figure 5 This is a partial structural breakdown diagram of the control structure of the present invention;

[0050] Figure 6 for Figure 5 Enlarged schematic diagram of part A;

[0051] Figure 7 This is a schematic diagram of the functional modules and control structure of the present invention;

[0052] Figure 8 This is a partial structural diagram of the functional modules and control structure of the present invention;

[0053] Figure 9 This is a partial structural breakdown diagram of the functional modules and control structure of the present invention;

[0054] Figure 10 This is a partial structural cross-sectional schematic diagram of the functional modules and control structure of the present invention;

[0055] Figure 11 This is a schematic cross-sectional view of the ring block and slip ring of the present invention;

[0056] Figure 12 This is a partial structural diagram of the control structure of the present invention;

[0057] Figure 13 This is a schematic diagram of the lower mold and functional module of the present invention when filling the second mixture.

[0058] Explanation of the labels in the diagram:

[0059] 1. Outer ring layer; 2. Inner ring layer; 3. Intermediate layer; 4. Upper mold; 5. Lower mold; 6. Functional module; 7. Control structure;

[0060] 41. Protrusion;

[0061] 51. Annular cavity; 52. Adaptive annular groove; 53. Sliding cavity; 54. Mounting cavity A; 55. Horizontal groove; 56. Sliding groove; 57. Mounting cavity B;

[0062] 61. Corner block A; 62. Corner block B; 63. Iris control unit; 631. Movable rod; 632. Slip ring; 633. Rotating groove; 634. Radial guide groove; 635. Rotating ring; 636. Angled guide groove; 637. Snap-fit ​​groove A;

[0063] 71. Rotary drum; 711. Threaded groove; 712. Snap-fit ​​groove B; 72. Ring block; 720. Threaded block; 721. Movable groove; 722. Movable block; 723. Spring; 724. Snap-fit ​​block A; 725. Snap-fit ​​block B; 73. Sliding bar; 731. Trapezoidal groove; 732. Trapezoidal block; 733. Displacement guide groove; 734. Guide block; 735. Movable circular groove; 736. Movable shaft; 737. Threaded guide groove; 738. Ball block; 739. Turntable; 74. Snap-fit ​​slider; 75. Motor; 76. Center gear; 77. Double-sided gear ring; 78. Side gear; 79. Side gear ring. Detailed Implementation

[0064] like Figures 1 to 13As shown, the present invention relates to a lightweight refractory brick with controllable closed-cell ratio, comprising an outer ring layer 1, an inner ring layer 2, and an intermediate layer 3. The outer ring layer 1 and the inner ring layer 2 are both formed by sintering a first mixture. The intermediate layer 3 is sandwiched between the outer ring layer 1 and the inner ring layer 2, and is formed by sintering a second mixture. The first mixture and the second mixture contain the same base material, and the first mixture contains a first content of solid combustible material, and the second mixture contains a second content of solid combustible material, the second content being greater than the first content, and the first content being ≥0. The solid combustible material burns away during the sintering process, forming pores in the outer ring layer 1, the inner ring layer 2, and the intermediate layer 3, respectively, so that the closed-cell ratio of the intermediate layer 3 is greater than that of the outer ring layer 1 and the inner ring layer 2. The interface between the intermediate layer 3 and the outer ring layer 1, and the interface between the intermediate layer 3 and the inner ring layer 2, are both non-smooth, unevenly interlocking. This invention provides an intermediate layer 3 containing a higher content of solid combustible material between the outer ring layer 1 and the inner ring layer 2. After sintering, this intermediate layer 3 forms closed pores, ensuring the stability of the pore structure. The intermediate layer 3 also achieves a lower thermal conductivity and excellent thermal insulation performance due to its high closed-pore ratio. Meanwhile, the outer ring layer 1 and the inner ring layer 2 maintain high strength and erosion resistance due to their low closed-pore ratios. This balances the strength of the refractory brick body with its thermal insulation performance. Furthermore, the non-smooth, uneven interlocking interface between the intermediate layer 3, the inner ring layer 2, and the outer ring layer 1 significantly increases the interlayer contact area, preventing delamination and cracking caused by differences in thermal expansion coefficients. This ensures the overall structural stability and thermal shock stability of the composite brick, solving the technical problem of unstable pore structure and difficulty in balancing strength and thermal insulation in refractory bricks.

[0065] A method for preparing a lightweight refractory brick with controllable closed-pore ratio by stabilizing its micropores includes the following steps:

[0066] S1. Ingredients mixing;

[0067] Provide basic billet and solid combustible material, mix the solid combustible material with the basic billet in different proportions to prepare the first mixture and the second mixture respectively;

[0068] S2, layered filling and pressing;

[0069] A layered filling method is adopted, in which the first mixture is filled into the outer mold cavity and the inner mold cavity of the refractory brick mold, and the second mixture is filled into the middle mold cavity between the outer mold cavity and the inner mold cavity, forming a composite green body composed of an outer ring layer 1 green body, a middle layer 3 green body and an inner ring layer 2 green body. The composite green body is pressed to make the outer ring layer 1 green body, the middle layer 3 green body and the inner ring layer 2 green body tightly bonded together.

[0070] S3, Drying;

[0071] The pressed composite green body is dried to remove free moisture;

[0072] S4, sintering;

[0073] The dried composite green body is sintered, and the solid combustible material burns away during the sintering process, forming pores in the outer ring layer 1, inner ring layer 2 and middle layer 3 respectively.

[0074] In step S2, the refractory brick mold includes: upper mold 4, lower mold 5, functional module 6 and control structure 7.

[0075] The bottom of the upper mold 4 has a square structure with four ring-shaped protrusions 41.

[0076] The lower mold 5 has a square structure at the top with four annular cavities 51. The protrusion 41 is movable and fits with the annular cavity 51. The bottom of the annular cavity 51 has an adapter annular groove 52. The bottom of the adapter annular groove 52 is connected to an annular sliding cavity 53. The bottom ends of the four sliding cavities 53 are connected through the mounting cavity A54. The lower mold 5 has a transverse groove 55. The transverse groove 55 is connected to the sliding cavity 53 through the sliding groove 56. The bottom of the lower mold 5 has a mounting cavity B57.

[0077] Several functional modules 6 are respectively disposed on several annular cavities 51, including several corner blocks A61 and several corner blocks B62 arranged in an annular and equally spaced structure. Corner blocks A61 and corner blocks B62 have the same cross-sectional shape. Two adjacent corner blocks A61 are fixedly connected, so that several corner blocks A61 form a closed fixed ring. The fixed ring is slidably disposed on the matching annular groove 52. Two adjacent corner blocks B62 are slidably connected, so that several corner blocks B62 form a closed movable ring. The movable ring is disposed on the annular cavity 51 and slidably engages with the matching annular groove 52. The bottom end of the fixed ring is provided with an iris control unit 63 for controlling the expansion and contraction of the movable ring. The iris control unit 63 includes several movable rods 631, a slip ring 632, several radial guide grooves 634, and a rotating ring 635. The movable rods 631 are rotatably mounted on the bottom ends of several corner blocks B62. The slip ring 632 is slidably mounted in the sliding cavity 53 and fixedly connected to the bottom end of the fixed ring body. A rotating groove 633 is opened at the bottom end of the slip ring 632. Several radial guide grooves 634 are opened on several corner blocks A61 and are connected to the rotating groove 633. The movable rods 631 are movably connected to the radial guide grooves 634. The rotating ring 635 is rotatably mounted on the top end of the rotating groove 633. Several oblique guide grooves 636 are opened at the top end of the rotating ring 635 in a ring-shaped, equally spaced structure. The bottom ends of the movable rods 631 are movably connected to the oblique guide grooves 636. A snap-fit ​​groove A637 communicating with the rotating groove 633 is opened on the bottom surface of the slip ring 632.Through the above-described configuration, in the initial state, the bottom end of the movable ring is flush with the bottom end of the ring cavity 51. The outer surface of the movable ring and the outer side of the ring cavity 51 form an outer mold cavity, and the inner surface of the movable ring and the inner side of the ring cavity 51 form an inner mold cavity for filling the first mixture. After filling the first mixture, the upper mold 4 is moved so that the top of the protrusion 41 contacts the top of the movable ring. The rotating ring 635 is rotated, changing the gap position of the intersecting inclined guide groove 636 and radial guide groove 634. This causes the movable rod 631 to move relative to the radial guide groove 634, causing several corner blocks B62 to move synchronously, resulting in the expansion and contraction of the movable ring. When the movable ring shrinks, its inner surface initially compacts the first mixture in the inner mold cavity. When the movable ring expands, its outer surface initially compacts the first mixture in the outer mold cavity, preventing loose powder from collapsing or mixing in subsequent processes. Furthermore, it can be adjusted according to... Based on actual needs, the expansion and contraction range of the movable ring and the amount of filler material in the first mixture are designed to change the relative volume of the outer ring layer 1, the inner ring layer 2, and the middle layer 3. This allows for flexible adjustment of the closed-cell rate and the thickness ratio of the three layers in the refractory brick, thereby controlling the overall strength and thermal insulation performance of the brick as needed. After initial compaction, the movable ring is driven to return to its initial shape. Then, the iris control unit 63, the fixed ring, and the movable ring are driven to move, so that the top of the movable ring is flush with the bottom of the ring cavity 51. This causes the gap between the initially compacted first mixture on both the inner and outer sides to form a central mold cavity with wavy surfaces on both sides. After removing the upper mold 4 and filling the central mold cavity with the second mixture, the upper mold 4 is moved, so that the protrusion 41 is pressed into the ring cavity 51 to perform final overall pressing of the three-layer composite green brick, so that the outer ring layer 1, the middle layer 3, and the inner ring layer 2 are tightly combined, and the brick is given its final shape and density.

[0078] The control structure 7 is located inside the lower mold 5 and has several lifting and rotating ends, which are respectively fixedly connected to the input ends of several iris control units 63. Specifically, the control structure 7 includes a rotating cylinder 71 and a ring block 72, a slide bar 73 and four snap-fit ​​sliders 74, a motor 75, a central gear 76, a double-sided toothed ring 77 and four side toothed rings 79.

[0079] A rotating drum 71 is rotatably mounted on the inner surface of the sliding cavity 53. The surface of the rotating drum 71 has several threaded grooves 711 arranged in an annular, equally spaced structure. A snap-fit ​​groove B712 is provided at the top of the rotating drum 71. A ring block 72 is rotatably mounted at the bottom end of the rotating groove 633 and fixedly connected to the bottom end of the rotating ring 635. The lifting and rotating end is composed of the ring block 72. The inner surface of the ring block 72 has several threaded blocks 720 fixedly mounted in an annular, equally spaced structure. These threaded blocks 720 are movably connected to the threaded grooves 711. Through the above arrangement, when the rotating drum 71 rotates relative to the ring block 72, the threaded grooves 711 and the threaded blocks 720 engage in a helical transmission, driving the ring block 72 and the rotating ring 635 fixedly connected to it to rise and fall axially. This, in turn, drives the sliding ring 632, the fixed ring body, and the movable ring body to rise and fall synchronously, achieving control over the relative position between the top end of the movable ring body and the bottom end of the ring cavity 51.

[0080] A movable groove 721 is provided inside the ring block 72, and a movable block 722 is movably connected inside the movable groove 721. Both ends of the movable groove 721 are provided with through grooves. The movable block 722 and the movable groove 721 are elastically connected by a spring 723. A snap-fit ​​block A724 and a snap-fit ​​block B725 are respectively fixed at both ends of the movable block 722. Both snap-fit ​​blocks A724 and B725 are adapted to the ring block 72. Snap-fit ​​block A724 extends out of the through groove and snaps into the snap-fit ​​groove A637. Snap-fit ​​block B725 extends out of the through groove and snaps into the snap-fit ​​groove B712. With the above-described configuration, in the initial state, the spring 723 pushes the movable block 722, causing the locking block A724 to remain locked with the locking groove A637, while the locking block B725 disengages from the locking groove B712. At this time, the ring block 72 is fixedly connected to the rotating ring 635, but is relatively independent of the rotating cylinder 71. When the rotating cylinder 71 rotates, it only drives the ring block 72 and the rotating ring 635 to rise and fall, which is used to adjust the axial position of the movable ring body.

[0081] The slider 73 is slidably disposed in the transverse groove 55. Four trapezoidal grooves 731 are opened on the slider 73 at positions opposite to the four slide grooves 56. A trapezoidal block 732 is movably disposed on the trapezoidal groove 731. A displacement guide groove 733 is opened on the trapezoidal block 732. A guide block 734 is movably connected to the displacement guide groove 733. The guide block 734 is fixedly connected to the slider 73. The displacement guide groove 733 is composed of an inclined guide groove and a transverse guide groove connected together. The inclined guide groove is opened on the inclined surface of the trapezoidal groove 731. The transverse guide groove is opened at one end of the trapezoidal block 732 near the trapezoidal groove 731. Four snap-fit ​​sliders 74 are slidably disposed on the four slide grooves 56 respectively. The snap-fit ​​sliders 74 are fixedly connected to the trapezoidal grooves 731. The snap-fit ​​sliders 74 are snap-fitted with the snap-fit ​​grooves A637. Through the above-described configuration, when the movable ring rises to the point where its bottom end is flush with the bottom end of the ring cavity 51, the slide bar 73 moves horizontally, causing the trapezoidal block 732 to undergo axial displacement relative to the slide bar 73. When the trapezoidal block 732 moves, it drives the snap-fit ​​slider 74 to slide along the slide groove 56 and insert into the snap-fit ​​groove A637, causing the snap-fit ​​block A724 to disengage from the snap-fit ​​groove A637. At the same time, the snap-fit ​​block B725 inserts into the snap-fit ​​groove B712 to form a snap-fit. At this time, the ring block 72 and the rotating cylinder 71 are fixedly connected through the cooperation of the snap-fit ​​block B725 and the snap-fit ​​groove B712. At this time, the rotating cylinder 71 rotates and drives the ring block 72, which is used to drive the movable ring to rotate during subsequent demolding.

[0082] A movable circular groove 735 is provided at one end of the slide bar 73. A movable shaft 736 is movably mounted on the movable circular groove 735. At least one threaded guide groove 737 is provided on the surface of the movable shaft 736. A ball block 738 is movably mounted on the threaded guide groove 737. The ball block 738 is rotatably connected to the movable circular groove 735. The movable shaft 736 passes through the lower mold 5 away from the movable circular groove 735 and is fixed to a turntable 739. The movable shaft 736 is rotatably connected to the lower mold 5. Through the above arrangement, when the turntable 739 rotates, it drives the movable shaft 736 to rotate synchronously. The threaded guide groove 737 on the surface of the movable shaft 736 and the ball block 738 form a helical transmission engagement, thereby driving the slide bar 73 to move horizontally along the transverse groove 55.

[0083] A motor 75 is fixedly mounted on a mounting cavity B57. A central gear 76 and a double-sided gear ring 77 are rotatably mounted on a mounting cavity A54 with an inner-outer structure. The bottom end of the central gear 76 passes into the mounting cavity B57 and is fixedly connected to the output shaft of the motor 75. The central gear 76 and the inner surface of the double-sided gear ring 77 are meshed and connected through several side gears 78. The side gears 78 are rotatably connected to the mounting cavity B57. Four side gear rings 79 are respectively fixed to the bottom ends of four rotating drums 71, and the side gear rings 79 are meshed and connected to the outer surface of the double-sided gear ring 77. Through the above arrangement, when the output shaft of the motor 75 is rotated by an external control mechanism, the central gear 76 rotates. The central gear 76 drives the double-sided gear ring 77 to rotate synchronously through several side gears 78. The outer surface of the double-sided gear ring 77 drives the four rotating drums 71 to rotate synchronously through meshing with the four side gear rings 79.

[0084] The embodiments disclosed in this invention are preferred embodiments, but are not limited thereto. Those skilled in the art can easily understand the spirit of this invention based on the above embodiments and make different extensions and variations, but as long as they do not depart from the spirit of this invention, they are all within the protection scope of this invention.

Claims

1. A lightweight refractory brick with controllable closed-cell ratio, characterized in that, include: The outer ring layer (1) is formed by sintering the first mixture; The inner ring layer (2) is formed by sintering the first mixture; The intermediate layer (3) is sandwiched between the outer ring layer (1) and the inner ring layer (2) and is formed by sintering the second mixture; The first mixture and the second mixture contain the same base material, and the first mixture contains a first amount of solid combustible material, the second mixture contains a second amount of solid combustible material, the second amount is greater than the first amount, and the first amount is ≥0; Solid combustible materials burn and disappear during sintering, forming pores, which makes the closed-pore ratio of the intermediate layer (3) greater than that of the outer ring layer (1) and the inner ring layer (2); The interface between the intermediate layer (3) and the outer ring layer (1), and the interface between the intermediate layer (3) and the inner ring layer (2) are both non-smooth, uneven, and interlocking.

2. A method for preparing a lightweight refractory brick with controllable closed-pore ratio as described in claim 1, characterized in that, Includes the following steps: S1. Ingredients are mixed; A basic blank and a solid combustible material are provided. The solid combustible material is mixed with the basic blank in different proportions to prepare a first mixture and a second mixture, respectively. S2, layered filling and pressing; Using a layered filling method, the first mixture is filled into the outer mold cavity and the inner mold cavity of the refractory brick mold, and the second mixture is filled into the middle mold cavity between the outer mold cavity and the inner mold cavity, forming a composite green body composed of an outer ring layer (1) green body, a middle layer (3) green body and an inner ring layer (2) green body. The composite green body is pressed to make the outer ring layer (1) green body, the middle layer (3) green body and the inner ring layer (2) green body tightly bonded. S3, Drying; The pressed composite green body is dried to remove free moisture; S4, sintering; The dried composite green body is sintered, and the solid combustible material burns away during the sintering process, forming pores in the outer ring layer (1), the inner ring layer (2) and the middle layer (3) respectively.

3. The method for preparing lightweight refractory bricks with controllable closed-pore ratio according to claim 2, characterized in that, In step S2, the refractory brick mold includes: The upper mold (4) has four ring-shaped protrusions (41) fixed at the bottom of the square structure. The lower mold (5) has a square structure at the top with four annular cavities (51) in the shape of a ring. The protrusion (41) is movable and fits the annular cavity (51). The bottom end of the annular cavity (51) is provided with a matching annular groove (52). Several functional modules (6) are respectively disposed on several annular cavities (51), including several corner blocks A (61) and several corner blocks B (62) arranged in an annular and equally spaced structure. The corner blocks A (61) and the corner blocks B (62) have the same cross-sectional shape. Two adjacent corner blocks A (61) are fixedly connected, so that several corner blocks A (61) form a closed fixed ring. The fixed ring is slidably disposed on the adapter ring groove (52). Two adjacent corner blocks B (62) are slidably connected, so that several corner blocks B (62) form a closed movable ring. The movable ring is disposed on the annular cavity (51) and slidably engaged with the adapter ring groove (52). The bottom end of the fixed ring is provided with an iris control unit (63) for controlling the expansion and contraction of the movable ring. The control structure (7) is located inside the lower mold (5) and has several lifting and rotating ends. The several lifting and rotating ends are respectively fixedly connected to the input ends of several iris control units (63). In the initial state, the bottom end of the movable ring is flush with the bottom end of the ring cavity (51). The outer mold cavity is formed by the outer side of the movable ring and the outer side of the ring cavity (51), and the inner mold cavity is formed by the inner side of the movable ring and the inner side of the ring cavity (51). After the first mixture is filled, the control structure (7) drives the movable ring to expand and contract through the iris control unit (63). When the movable ring shrinks, its inner surface initially compacts the first mixture in the inner mold cavity. When the movable ring expands, its outer surface initially compacts the first mixture in the outer mold cavity. After initial compaction, the control structure (7) drives the movable ring to return to its initial shape through the iris control unit (63). Then, the iris control unit (63) drives the fixed ring and the movable ring to move until the top of the movable ring is flush with the bottom of the ring cavity (51), so that the gap between the first mixture on the inner and outer sides is initially compacted to form a central mold cavity with wavy surfaces on both sides.

4. The method for preparing lightweight refractory bricks with controllable closed-pore ratio according to claim 3, characterized in that, The bottom end of the adapter ring groove (52) is connected to a ring-shaped sliding cavity (53), and the bottom ends of the four sliding cavities (53) are connected through the mounting cavity A (54). A transverse groove (55) is opened in the lower mold (5), and the transverse groove (55) is connected to the sliding cavity (53) through the sliding groove (56). A mounting cavity B (57) is opened at the bottom end of the lower mold (5).

5. The method for preparing lightweight refractory bricks with controllable closed-pore ratio according to claim 4, characterized in that, The iris control unit (63) includes several movable rods (631), a slip ring (632), several radial guide grooves (634), and a rotating ring (635). Several movable rods (631) are rotatably disposed at the bottom ends of several corner blocks B (62). The slip ring (632) is slidably disposed in the sliding cavity (53) and fixedly connected to the bottom end of the fixed ring body. A rotating groove (633) is opened at the bottom end of the slip ring (632). Several radial guide grooves (634) are opened on several corner blocks A (61) and communicate with the rotating grooves (633). The movable rods (631) are movably connected to the radial guide grooves (634). The rotating ring (635) is rotatably disposed at the top end of the rotating groove (633). Several oblique guide grooves (636) are opened at the top end of the rotating ring (635) in a ring-shaped, equally spaced structure. The bottom ends of several movable rods (631) are movably connected to several oblique guide grooves (636).

6. The method for preparing lightweight refractory bricks with controllable closed-pore ratio according to claim 5, characterized in that, The control structure (7) includes a rotating cylinder (71) and a ring block (72). The rotating cylinder (71) is rotatably disposed on the inner surface of the sliding cavity (53). The surface of the rotating cylinder (71) has a number of threaded grooves (711) with an annular and equally spaced structure. The ring block (72) is rotatably disposed at the bottom end of the rotating groove (633) and fixedly connected to the bottom end of the rotating ring (635). The inner surface of the ring block (72) has a number of threaded blocks (720) with an annular and equally spaced structure. The number of threaded blocks (720) are movably connected to the number of threaded grooves (711) respectively. The lifting and rotating end is composed of the ring block (72).

7. The method for preparing lightweight refractory bricks with controllable closed-pore ratio according to claim 6, characterized in that, The ring block (72) has a movable groove (721) inside, and a movable block (722) is movably connected inside the movable groove (721). Both ends of the movable groove (721) have through grooves. The movable block (722) and the movable groove (721) are elastically connected by a spring (723). Both ends of the movable block (722) are respectively fixed with a snap-fit ​​block A (724) and a snap-fit ​​block B (725). Both the snap-fit ​​block A (724) and the snap-fit ​​block B (725) are adapted to the ring block (72). The bottom surface of the slip ring (632) is provided with a snap-fit ​​groove A (637) that communicates with the rotating groove (633), and the snap-fit ​​block A (724) passes through the through groove and snaps into the snap-fit ​​groove A (637); The top of the rotating drum (71) is provided with a snap-fit ​​groove B (712), and the snap-fit ​​block B (725) passes through the through groove and engages with the snap-fit ​​groove B (712).

8. The method for preparing lightweight refractory bricks with controllable closed-pore ratio according to claim 7, characterized in that, The control structure (7) also includes a slider (73) and four snap-fit ​​sliders (74). The slider (73) is slidably disposed in the transverse groove (55). Four trapezoidal grooves (731) are opened on the slider (73) relative to the four grooves (56). A trapezoidal block (732) is movably disposed on the trapezoidal groove (731). A displacement guide groove (733) is opened on the trapezoidal block (732). A guide block (734) is movably connected to the displacement guide groove (733). The guide block (734) is fixedly connected to the slider (73). The displacement guide groove (733) is composed of an inclined guide groove and a horizontal guide groove connected together. The inclined guide groove is opened on the inclined surface of the trapezoidal groove (731), and the horizontal guide groove is opened at one end of the trapezoidal block (732) near the trapezoidal groove (731). The four snap-fit ​​sliders (74) are respectively slidably disposed on the four slide grooves (56). The snap-fit ​​sliders (74) are fixedly connected to the trapezoidal groove (731) and the snap-fit ​​sliders (74) are snap-fitted into the snap-fit ​​groove A (637).

9. The method for preparing lightweight refractory bricks with controllable closed-pore ratio according to claim 8, characterized in that, The slide bar (73) has a movable circular groove (735) at one end, and a movable shaft (736) is movably mounted on the movable circular groove (735). At least one threaded guide groove (737) is provided on the surface of the movable shaft (736), and a ball block (738) is movably mounted on the threaded guide groove (737). The ball block (738) is rotatably connected to the movable circular groove (735). The movable shaft (736) passes through the lower mold (5) away from the movable circular groove (735) and is fixedly mounted on a turntable (739). The movable shaft (736) is rotatably connected to the lower mold (5).

10. The method for preparing lightweight refractory bricks with controllable closed-pore ratio according to claim 6, characterized in that, The control structure (7) also includes a motor (75), a central gear (76), a double-sided gear ring (77), and four side gear rings (79). The motor (75) is fixed on the mounting cavity B (57). The central gear (76) and the double-sided gear ring (77) are rotatably mounted on the mounting cavity A (54) with an inner and outer structure. The bottom end of the central gear (76) passes into the mounting cavity B (57) and is fixedly connected to the output shaft of the motor (75). The central gear (76) and the inner surface of the double-sided gear ring (77) are meshed and connected by several side gears (78). The side gears (78) are rotatably connected to the mounting cavity B (57). Four side gear rings (79) are fixed on the bottom ends of the four rotating cylinders (71) respectively. The side gear rings (79) are meshed and connected to the outer surface of the double-sided gear ring (77).

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