Composite clay material, its use, additives and method for manufacturing clay building materials

Abstract

A composite clay material is described having a clay fraction of at least 35 wt% and an additive comprising a gelatin glue fraction and / or a gelling agent fraction and an acid fraction.

Description

Technical Field

[0001] This invention relates to a composite clay material, its uses, an additive, and a method for manufacturing clay building materials. Background Technology

[0002] The purpose of using clay bricks in construction is known. A clay brick is a rectangular block of clay, hand-shaped or molded and air-dried, used in clay construction. Sand is mixed with clay-rich clay, sometimes with the addition of fibrous materials such as straw or animal hair, and substances for plant nutrition such as camel dung, bark, and horse manure. Plant fibers reduce weight, improve insulation, and impart tensile strength, thus reducing cracking during the drying process. In heavy rain, clay bricks will evaporate moisture again. Clay walls must be protected from continuous moisture and rainwater. Through firing, clay bricks become bricks, terracotta bricks, or calcined bricks.

[0003] Clay is used to make air-dried bricks (green bricks), and this clay is typically mixed with sand, plant fibers, or other fillers. Too much sand reduces the brick's load-bearing capacity, while too much clay causes it to crack. The amount of dried or soaked straw added must also be precisely measured. The well-kneaded, sticky clay mixture is traditionally pressed into rectangular wooden molds, but nowadays it is often pressed into metal molds. Once the material has solidified, the mold frame is removed. For drying, bricks with a high clay content are usually stored in a cool place, as rapid moisture evaporation can cause cracking. However, the bricks can also be dried by direct exposure to sunlight.

[0004] To efficiently produce clay bricks with improved load-bearing capacity, mechanical presses can be used. Machine-pressed bricks are called compressed clay blocks (CEB). Bricks stabilized with cement or other binders are called compressed stabilized clay blocks (CSEB) or stabilized clay blocks (SEB). Clay bricks are generally fully recyclable. Mortar and plaster residues in the clay can usually be easily separated. Whole and half bricks can be rebuilt. Broken bricks are soaked in water and further processed into bricklaying mortar, plaster, or new clay bricks.

[0005] DE20221176.2 discloses a ceiling and wall element with an integrated cooling or heating piping system for heating walls and / or ceilings according to a radiant heating system, wherein the ceiling and wall element is designed as a static self-supporting component. The structural element is prefabricated. The main cooling side and main heating side of the component can be determined based on the location of the installed piping.

[0006] DE102016101934A1 relates to a thermally conductive plaster, the base of which is clay and contains additives including mineral and / or metal and / or ceramic particles to improve thermal conductivity.

[0007] DE202009006566U1 relates to a composition for filling joints, comprising a clay-loam mixture that has been incorporated into water as a binder and is packaged in a ready-to-use form with a processable consistency.

[0008] DE19736526A1 relates to a building material mixture consisting of unburned clay and / or clay blended with mechanically prepared bast fiber plant fibers, wherein the building material is free of synthetic and / or non-biodegradable additives.

[0009] EP1172344A2 relates to a dry-process factory mortar based on clay powder, aggregates and other conventional additives, containing 20 to 60% by weight of solidified gypsum.

[0010] The known disadvantages of clay are that it was designed for the manufacture of clay bricks for building, but no other possible applications were provided, and the material's range of uses and strength were insufficient. Summary of the Invention

[0011] Therefore, the objective of this invention is to provide a composite clay material and a clay building material that have improved mechanical properties and are easier to process.

[0012] The invention is solved by the subject matter of the independent claims. Advantageous embodiments and extensions are disclosed in the dependent claims, the specification, and the drawings.

[0013] This composite material contains at least 35% by weight of clay and additives containing a portion of gelatin and / or a portion of gelling agent and an acid portion. Its advantages include that clay building materials produced from this composite clay material are easier to process than natural clay, and also exhibit improved tensile strength, compressive strength, flexural tensile strength, adhesive strength, shear strength, and abrasion resistance. Furthermore, the flowability of the composite material and thus its processability are improved. The acid used lowers the processing temperature and mold susceptibility; the low concentration of acid has a relatively high water content and can be used for processing without the need for additional water addition.

[0014] In one embodiment, the additive contains at least one organic acid and / or inorganic acid, wherein the organic acid is particularly acetic acid, formic acid, lactic acid, tartaric acid, malic acid, or citric acid, and the inorganic acid is particularly hydrochloric acid, sulfuric acid, or nitric acid. It is preferred to use only organic acids because these acids are environmentally friendly and biodegradable.

[0015] Additives may contain additional water, provided that the viscosity is increased, depending on the respective further processing objectives. In particular, in formulations where the additive is present in dry or powder form and added to the clay or base clay in dry form, the addition of water is not only suitable but also necessary in order to set the desired composite processing properties for the manufacture of building materials (e.g., stone, load-bearing components, etc.).

[0016] In one improved embodiment, additives include sodium carbonate and / or sodium bicarbonate as pore-forming agents, thereby adjusting the porosity of the composite clay material. The porosity of the composite clay material is also reflected in the porosity of the finished product or clay building material after drying.

[0017] In one advantageous embodiment, the concentration of gelatin and / or gelling agent in the additive is between 3% by weight and 75% by weight, wherein the gelatin provides higher strength, water resistance, and flowability compared to plant-based gelling agents. The acid share is between 0.1% by weight and 97% by weight, the water share is between 0% by weight and 97% by weight, and the sodium carbonate and / or sodium bicarbonate share is between 0% by weight and 40% by weight, with the total of all components of the additive being 100% by weight.

[0018] If other additives or components are added to the additive, for example to improve flowability or change color and / or change mechanical properties, this does not preclude further additional components of the additive from being deducted from the total weight and not included in the percentage distribution.

[0019] In one embodiment, the gelling agent is alginic acid, sodium alginate, potassium alginate, ammonium alginate, calcium alginate, agar, carrageenan, locust bean gum, guar bean gum, tragacanth gum, xanthan gum, tara gum, gellan gum, pectin, cellulose powder, gelatin and / or modified starch.

[0020] To alter mechanical properties, plant fibers, particularly wood fiber, straw, hemp fiber, jute, sisal, and / or flax, can be added to composite clay materials. Other plant fibers, such as bamboo fiber, also contribute to improving the stability and mechanical properties of products made from composite clay materials.

[0021] In particular, composite clay materials are provided in the form of processable mixtures, for example, in a dry form with gelatin and / or gelling agents and acids, so that the viscosity can be adjusted by simply adding water and optional heat.

[0022] The composite clay material described in this manner is specifically used in the manufacture of clay building materials, wherein water and heat are supplied to the composite clay material until the mixture reaches the desired viscosity, particularly a viscosity greater than 100 mPas, i.e., a viscosity suitable for spraying, spreading, extruding, pressing, or initial shaping. The mixture of the composite clay material with water and optional heat is shaped as desired and then dried to obtain finished clay building products, such as clay bricks, clay boards, clay cardboard, lintels, ring anchors, etc.

[0023] The mixture is preferably applied in a pressing or extrusion die, or shaped by repeated layer-by-layer application and drying. The repeated layer-by-layer application and drying of the mixture results in a laminated structure within the clay building product, allowing for precise setting of final dimensions and mechanical properties.

[0024] To improve the mechanical properties of clay building products, in one improvement scheme, plant fibers and / or fabrics are introduced into the mixture and dried together with the composite clay material.

[0025] The additives used in the manufacture of composite clay materials and added to the base clay include 3% to 75% by weight of gelatin and / or gelling agent, 0.1% to 97% by weight of organic and / or inorganic acids, 0% to 97% by weight of water, and 0% to 40% by weight of sodium carbonate and / or sodium bicarbonate, totaling 100% by weight. If other materials are added to the base clay, these materials are not included in the weight balance.

[0026] In one embodiment, the water content of the additive is reduced so that the additive is in powder form. Alternatively, the additive is provided in liquid form, which can be supplied directly to the base clay or adjusted to the appropriate viscosity by adding water and optionally heat.

[0027] For the preparation of the base mixture of additives, gelatin glue (liquid), gelatin (liquid), gelatin glue granules / powder (dry), or gelatin in dried form can be used.

[0028] The liquid form is achieved by adding water, depending on the amount of gelatin used or the amount of heat (optional). If granules / powder are used, they can be soaked in measured amounts of water (pre-swelling) or added directly to the clay. Pre-swelling reduces the energy required for liquefaction, improves processability, and ensures uniform distribution in clay building materials.

[0029] Water may be used as pure drinking water, distilled water, river water, pond water, seawater, or added as a water mixture.

[0030] The mixture—gelatin granules / powder or gelatin and water—is then heated in a water bath to the necessary melting temperature until the granules / powder or gelatin liquefies. The mixture is then stirred to ensure the two components are evenly combined.

[0031] Adding one or more acids can reduce processing temperature and mold susceptibility.

[0032] The added acid dissolves the cell membranes of the gelatin / gelatin gel, ensuring a rapid reaction during heating and thus lowering the processing temperature. Simultaneously, depending on the amount and concentration of the added acid, an extremely low pH level ensures reduced or prevented mold growth.

[0033] As an acid, organic acids such as acetic acid, formic acid, lactic acid, tartaric acid, malic acid, and others, or inorganic acids such as hydrochloric acid, sulfuric acid, nitric acid, and others can be used. The acid should be added after the heating process, as it will evaporate at higher temperatures.

[0034] The above-described components and methods yield a so-called additive-based mixture, which can be used at different concentrations depending on the application. For example, if acetic acid is used in the additive, it may react with the lime naturally present in the clay. The resulting CO2 gas increases the pore volume. This volume is maintained by the stabilizing effect of the additive, preventing gas escape.

[0035] If the cavity volume needs to be further increased, a stronger reaction can be produced by adding sodium carbonate or sodium bicarbonate. CO2 is also generated in these reactions, thus increasing the cavity volume in the clay building material.

[0036] Sodium carbonate / sodium bicarbonate is mixed in powder form with dry or moist clay building materials / natural clay. The reaction is activated when additives such as gelatin, water, and acetic acid are added. The ratio of acetic acid to sodium carbonate / sodium bicarbonate must be matched with the clay, as there should be no sodium carbonate / sodium bicarbonate residue in the building materials.

[0037] The ingredients and methods mentioned in the preceding paragraphs yield an air-entraining agent, which can be used at different concentrations depending on the application.

[0038] As the acid content and water temperature in the base mixture increase, temporary fluidity of the clay building material is achieved upon addition. The lower viscosity of the gelatin used ensures better sliding properties of the clay components (clay, silt, and sand). Consequently, the consistency band gap, i.e., the distance between the clay's yield point and unfolding point, is reduced as needed without the need for additional water addition, allowing for longer processing times. After the drying process, the residual gelatin again ensures the aforementioned increased strength. This cooling agent can be used to manufacture, for example, clay fluidized mortar, clay filler, and clay fluidized bed mortar.

[0039] For base mixtures, air-entraining agents (or pore-forming agents), and condensers, the applicable conditions are: during the drying process, moisture evaporates, leaving only organic components.

[0040] Base mixtures, air-entraining agents, and condensers have a wide range of applications and varying effects. This wide range and varying effects stem from the diverse range of naturally occurring and industrially produced clay mixtures, various additives such as fibers, fabrics, and different aggregates, processing types (e.g., molding, extrusion processes), and other factors. For each application, the additives should be adjusted to achieve the optimal mixing ratio. Therefore, base mixtures, air-entraining agents, and condensers can be produced at different concentrations as needed.

[0041] The concentration of additives used in composite clay materials can be determined within the following spectrum (or range): Gelatin / Gelatin-gelling agent 3-75% by weight Acid 0.1-97% by weight Water 0-97% by weight Sodium carbonate / sodium bicarbonate 0-40 by weight.

[0042] The concentration data for additives refers to the weight percentage of gelatin or gelling agent. A 17% concentration means that the additive contains 17% by weight of gelatin and / or gelling agent. For example, for 1 kg of additive, use 170 g of bone glue, 30 g of 25% vinegar, and 800 g of water. For a 37% concentration, for example, use 370 g of bone glue, 67 g of 25% vinegar, and 563 g of water.

[0043] One application specifies adding 1% by weight of additive to the base clay, that is, 1 kg of additive added to 999 kg of clay.

[0044] When using 17% additive at a concentration of 1% by weight, 1 kg of additive is used per 1000 kg of composite clay material. Therefore, the composite clay material initially contains 0.17% by weight of gelatin, especially bone glue. Volatile components and water disappear accordingly during the drying process.

[0045] In this application, when the composite clay material is processed in a compression molding method, it can be measured that 0.17% by weight of gelatin in the composite clay material increases the flexural tensile strength or load by 50%.

[0046] In composite materials processed using a hand-mixing process, when the proportion of gelatin (e.g., bone glue) is 15% by weight, the flexural tensile strength or load can increase by up to 5000% compared to clay without additives.

[0047] In one application, for 300 kg of clay, 60 kg of water, 40 kg of bone glue, and 7 kg of vinegar (25% concentration) were used, and the mixture was processed by hand to produce load-bearing components. This resulted in a composite clay material with a bone glue concentration of 9.83% by weight and an additive concentration of 37.38%.

[0048] The base mixture, air-entraining agent, and condenser can be processed by atomization or direct addition into clay building materials or natural clay.

[0049] Depending on the type of clay building material produced, the amount of additives may vary for the same type of clay building material.

[0050] Taking commercially available clay boards as an example, adding 1% by weight of the base material mixture (17% solution) additive can achieve the following values: Molding process, pressing pressure 40N / mm 2 The load is from 1.5 N / mm 2Increased to 2.28 N / mm 2 Extrusion process, pressing pressure 13 N / mm 2 The load is from 1.5 N / mm 2 Increased to 1.71 N / mm 2 .

[0051] Application Examples Example 01: Clay Mortar The developed additive was added as a base mixture to conventional fiber-free clay mortar. After addition, a flexural tensile strength of 15 N / mm² was achieved. 2 Compressive strength 20 N / mm 2 With an adhesion strength of 2.4 N / mm 2 The expected strength depends on the amount and concentration of the additive, the type of clay particles, the gradation profile, the amount of mixing water, the type of reinforcing material added (e.g., natural fibers, wood cross-sections, geotextiles), the processing method, and the required parameters. Higher strength can be achieved through optimized particle size distribution and mixing.

[0052] Example 02: Surface protection of clay plaster, clay bricks, clay coatings, etc. The developed additive is used as a base mixture, for example at a concentration of 17%, and introduced into the atomizer. The sprayable additive is applied to the surface of the selected clay component to be protected. Depending on the surface properties and the required level of protection, one to multiple layers may be required. Adsorption may be slightly to significantly reduced depending on the application.

[0053] Taking commercially available clay boards as an example, after being treated with two layers of additives, the water penetration time is extended from 3 minutes to 25 hours.

[0054] Taking commercially available clay bricks as an example, in the immersion test, the dissolution time was extended from 11 minutes to 45 minutes.

[0055] Taking commercially available clay coatings as an example, by directly introducing 2% of the additive, it can be cleaned with a damp cloth without material peeling off. Standard testing shows an abrasion rate of less than 0.1g. If commercially available dry clay plaster is sprayed with the aforementioned additive, the surface exhibits very high abrasion resistance. Standard testing shows an abrasion rate of less than 0.1g.

[0056] Example 03: Clay Board The flexural tensile strength of commercially available clay (cardboard) boards is currently approximately 1.5 N / mm². 2 By adding, for example, 17% solution of the base material mixture and 1% of the clay mixture, the flexural tensile strength of clay (cardboard) sheets can be increased to 2.28 N / mm² during the compression molding process. 2 .

[0057] Example 04: Clay Filler Material For clay without added fibers, a condensing agent (37% concentration, 2% proportion) is mixed with clay mortar prepared according to the manufacturer's instructions at 40°C (mixed with water and additives). The spread is increased from 175 mm to beyond the edge area of ​​the measuring device.

[0058] Example 05: Clay insulation / porous clay bricks For clay without added fibers, add an air-entraining agent (25% concentration) at a 15% ratio. Bulk density (or coarse density) can range from 1600 kg / m³. 3 Reduced to 610 kg / m 3 At the same time, it still maintains 5N / mm 2 The compressive strength.

[0059] Example 06: Load-bearing clay / hybrid components To produce load-bearing clay components, high concentrations and large amounts of gelatin are used in the additives. The final product should have high strength and reduced susceptibility to moisture regain. Using reinforcing materials (such as bamboo fiber) combined with composite clay to achieve high adhesion strength, i.e., composite clay materials, can produce strength exceeding 20 N / mm². 2 The intensity value.

[0060] Taking a clay lintel with an unreinforced layered structure as an example Clay was mixed with a 20% solution of 37% additives and processed into slabs. After drying, the slabs were longitudinally cut into strips, for example, 11.5 cm wide. These strips were then bonded together in a layering system using the same clay (containing 20% ​​of the 37% additive solution) until the lintel dimensions were achieved. In testing, a lintel with dimensions of 1250 x 115 x 71 mm achieved a bending tensile strength of 13 N / mm. 2 and compressive strength 18.6 N / mm 2 .

[0061] Taking a layered structure of mixed clay lintels as an example Clay was mixed with a 20% solution of 37% additives and processed into boards. After drying, the boards were longitudinally cut into strips, for example, 11.5 cm wide. These strips were then bonded together with the inserted laminated boards in a layering system using the 20% solution of 37% additives until the lintel dimensions were achieved. In testing, a bending tensile strength of 21 N / mm was achieved. 2 Compressive strength 24 N / mm 2 .

[0062] Example 07: Sealing For example, clay is mixed with a 30% solution of a 37% additive. The resulting composite clay is applied to the limestone masonry in the ground area using a trowel to a thickness of, for example, 5 mm. After the composite clay dries, it is covered with a pre-compacted clay / clay layer (e.g., 10 cm thick), and the remaining pit is backfilled. When the composite clay comes into contact with groundwater, a gel-like layer forms on its surface, preventing water penetration.

[0063] In one test, a 5mm thick sealing layer was subjected to direct groundwater application for one week. Only the first 3mm of the composite clay was activated to expand. The underlying PS masonry remained completely unaffected by groundwater over time.

[0064] Example 08: Thin-walled clay molded products Example: Clay protective element reinforced with natural fibers For example, clay was mixed with a 30% solution of 37% additives. The resulting composite clay was then uniformly mixed with 5% by volume hemp cotton as a fiber reinforcement material. The finished mixture was then compacted to the desired shape. In testing, a hemisphere with a fixed frame was produced, measuring 500 x 500 x 150 cm (length x width x height), with a material thickness of 7 mm. The compressive strength was 22 N / mm². 2 .

[0065] Example 09: Injecting clay mortar For anchoring in clay structures, such as for bonding masonry anchor bolts, the clay is treated, for example, with a 25% to 40% additive solution, which has slight expansion properties. The resulting injected clay mortar can be injected into rearward-conical boreholes to bond the masonry anchor bolts. In tests, commercially available rammed earth walls showed a strength of 55 N / mm². 2 It failed under tensile load. The injector was undamaged.

[0066] Example 10: Clay in Furniture Making Example: Clay stool For example, clay is mixed with a 30% solution of 45% additives. The resulting composite clay is then uniformly mixed with 5% by volume hemp cotton as a fiber reinforcement material. Before introducing the finished composite clay material into the mold, for example, metal threaded sleeves are introduced as fixing points for the chair legs. The finished mixture is then compacted to the desired combined seat-back shape.

[0067] Example 11: Clay 3D Printing To use composite clay in 3D printing, a transportable clay is fed into the nozzle of the 3D printer. At the nozzle alone, additives, such as a 30% to 45% solution, are injected into the clay under high pressure. The clay exiting the printer nozzle gains high initial strength as it cools, allowing subsequent layers to be applied directly without material sagging. The not-yet-fully-dried surface of the composite clay results in a cohesive bond between the layers.

[0068] Example 12: Clay bricks Currently, the compressive strength of commercially available clay bricks is grade 6. By adding, for example, a 17% solution of the base material mixture and 1% of the clay mixture, the compressive strength of the clay bricks can be increased to 10 N / mm² during the pressing process. 2 The particle size distribution of clay contributes significantly to the increase in strength.

[0069] This invention enables a significant increase in the maximum possible load: Compressive strength up to 20 N / mm 2 It is commercially available clay (7.5 N / mm). 2 2.6 times Flexural tensile strength up to 15 N / mm 2 It is commercially available clay (0.31 N / mm). 2 50 times Adhesion strength up to 2.4 N / mm 2 It is commercially available clay (0.1 N / mm). 2 24 times Abrasion resistance: abrasion resistance is less than 0.01g, which is 1 / 70th of that of commercially available clay (0.7g). Water resistance varies depending on the size of the component; for example, a 4x4x16cm component lasts for 6 hours, while the standard duration is 5 minutes. Porosity 300 kg / m 3 It is commercially available clay (2000 kg / m³). 3 One-seventh of ).

[0070] Also disclosed is a composite clay material, its uses, a method for manufacturing clay building materials, and an additive for manufacturing the composite clay material. The clay can be purified using the additive. Clay building materials obtained in this manner specifically include clay wall mortar, clay plastering mortar, clay putty, clay reinforcing material, clay adhesive, clay leveling material, clay coating, rammed earth, clay bricks, clay (cardboard) boards, load-bearing components such as lintels, ring anchors, and optional other components. Clay building materials made from this composite clay material are suitable for installing underfloor heating, and in one embodiment include clay mortar for laying underfloor heating systems in a clay leveling layer.

[0071] For paving systems, clay mortar is used to bond different components together. Clay mortar includes additives, which can vary in quantity and composition, allowing for adaptability and flexibility to different base clays. These additives form additives that can alter the properties of clay building materials made from composite clay materials. Depending on the quantity, concentration, and mixing ratio of each component, parameters of the finished building material or product can be improved, such as tensile / compressive / flexural tensile / shear strength, abrasion resistance, and / or water resistance. Flowability, bond strength, and other properties such as the porosity of clay construction and natural clay can be increased several times. The properties of composite clay materials and clay aggregates are affected, and additives can even produce a foaming effect. The additives used are biodegradable and durable. Stabilizing and foaming additives can be added to clay mortar.

[0072] Additives can be added directly or by spraying to clay materials—industrially produced clay or naturally occurring clay—or applied to the surface of the clay.

[0073] For stabilization, improved flowability, or foaming of clay building materials, use the additives: bone glue granules, vinegar (25%), and water. The bone glue granules are either soaked in a measured amount of water and swollen for 24 hours, or processed directly without pre-swelling. The mixture of bone glue and water is heated in a water bath to 50-60°C and continuously stirred until the bone glue granules liquefy and mix with the water. Vinegar is then added while stirring. The vinegar dissolves the cell membranes in the bone glue, making it processable at room temperature. When the additive is added to clay building materials, the clay absorbs and binds to it through its high cohesiveness, forming crystalline compounds. This improves overall stability. Slight swelling of the clay mixture is possible due to the small amount of vinegar added, but the addition of vinegar is necessary to prevent mold formation during the drying process.

[0074] The base mixture specifically includes 300g of clay mortar, 40g of bone glue granules, 60g of tap water, and 7g of vinegar (25%).

[0075] The measured intensity is: Flexural tensile strength = 10 N / mm 2 Compressive strength = 20 N / mm 2 .

[0076] Alternatively, the 40g of bone glue in the original formula can be replaced with other gelatin glues or pure gelatin. Impure gelatin glues (such as bone glue, hide glue, rabbit glue, fish glue) still contain residues (such as meat scraps, animal fur, and solvents used in production). Purified gelatin glue is pure gelatin and therefore virtually tasteless. Depending on the purity of the glue / gelatin used, performance in clay products may vary. In such cases, for example, increased mold growth, reduced strength, lower processing temperatures, or increased processing difficulty may occur.

[0077] To improve resistance and adhesion, clay mortars and clay putties containing additives can be used, for example. Any clay manufacturer's base mortar or clay putty can be used in combination with its developed additives. The increase in strength and bond strength can be controlled by the amount of additive. Performance will vary depending on the manufacturer's base mortar, based on its naturally occurring mixing ratios, and must be determined before each distribution.

[0078] To improve fluidity, clay mortar, clay leveling compounds, and / or clay fillers can be used. For example, any desired base mortar or base mortar or clay putty from a clay manufacturer can be combined with additives (increasing the water content). The improvement in fluidity can be controlled by the amount of water. Shrinkage cracking may occur depending on the clay content of the base material. Performance will vary depending on the manufacturer's base material, based on its naturally occurring mixing ratio, and must be determined before each distribution.

[0079] To achieve clay insulation, the amount of vinegar can be increased while the amount of water added can be decreased, creating a foaming effect in the clay. Adding lye to the clay raw material as needed can enhance the foaming process. This results in larger pores; lye is mixed into the clay building material, and then the additives are added only shortly before processing. As a result, depending on the amount of vinegar and lye, the load-bearing capacity and density of the clay decrease, forming a foam-like structure. From this mixture, insulation boards can be produced using molds. These can be used for floor or wall insulation.

[0080] One embodiment may specifically include 1200g of clay mortar, 120g of bone glue granules, 70g of tap water, and 130g of vinegar (25%), as well as 12g of caustic soda. The strength may, for example, be a flexural tensile strength of 5.5 N / mm². 2 and compressive strength 12N / mm 2 .

[0081] To improve resistance and adhesion, in the case of lintels and ring anchors (using additional reinforcing materials such as bamboo poles) and clay bricks, the developed additives are combined with a base mortar from any desired clay manufacturer. Load-bearing components are made from single thin layers. For creation, slabs approximately 10 mm thick with the desired length / width are prepared from the mixture. After the drying process, the individual panels are bonded together layer by layer using the same material until the desired component dimensions are achieved. The increase in strength and bond strength can be controlled by the amount of additive. Performance will vary depending on the manufacturer's base material, based on its naturally occurring mixing ratio, and must be determined before each distribution.

[0082] To improve resistance and load transfer, in clay building boards or clay paperboard (with load transfer), any desired base mortar, clay putty, any desired clay building board mixture, or rammed earth from the clay manufacturer is used in combination with developed additives and inserted reinforcing materials (such as jute fabric) or paper bonded to the outside as in gypsum board. The increase in strength and bond strength can be controlled by the amount of additives. To prevent high-strength materials from crumbling during tightening or nailing, the proportion of clay in the original clay building material must be increased. This results in a fracture mode similar to gypsum board. Performance will vary depending on the manufacturer's base material, based on its naturally occurring mixing ratio, and must be determined before each distribution.

[0083] If the additive is to be stored / contained / transported for future use, it is filled into a suitable container and sealed after the production process at the desired temperature of 50°C-60°C. Upon cooling, a negative pressure is created inside the container to preserve the additive. Depending on the required processing temperature, the additive may need to be briefly heated in a hot water bath.

[0084] To create clay underfloor heating, i.e., underfloor heating within a clay leveling layer, clay mortar with additives and precast clay modules, particularly rammed earth modules, are used. To create the (rammed earth) clay modules, 7.5 kg of 0 / 8 rammed earth is used, mixed with the water ratio specified by the manufacturer, and introduced into a steel mold with internal dimensions of width x length x height = 300 x 400 x 100 mm. The rammed earth mixture is processed without additives. The rammed earth mixture is pressed in the steel mold using a suitable press at 13.33 N / mm². 2 Press, demold, and then dry on suitable supports. To prevent module warping, the support surface must be as small as possible during drying. The dimensions of the pressed module are length x width x height = 400 x 300 x 27 mm. Dried modules can be stacked and stored on standard European pallets.

[0085] For underfloor heating installation, begin with clay filler material. Depending on the structure (floating, composite), apply it to the base layer, and then lay the first layer of clay modules on top of the filler material. Use T-joints for the installation. Bond the joints with added clay mortar during installation. Then, cut the remaining clay modules to pipe spacing (e.g., 95x400mm). These cut clay modules form the second layer, in which the heating pipes are laid. Shortly before applying the added clay mortar, brush a small amount of water onto the surface of the first layer of clay modules to create a bond between the added clay mortar and the clay modules. Subsequently, lay the cut clay modules into the added clay mortar at pipe spacing, defining the joints of the heating pipes using spacing-maintaining methods (e.g., remaining sections of the heating pipes). Remove any excess added mortar from the joints to allow for standard installation of the heating pipes after drying. If the second layer is fully installed, allow it to dry for 1-2 days, depending on the indoor climate. After the drying time, heating pipes (e.g., PE-RT, PE-XE, PE-XC, aluminum-plastic composite pipes) are introduced into the newly applied bed of additive-coated clay mortar in the laying joints, and then covered with additive-coated clay mortar. Immediately before applying the additive-coated clay mortar, a small amount of water is brushed onto the surface of the clay modules again to create a bond between the additive-coated clay mortar and the clay modules. The third layer of additive-coated clay mortar consists of clay modules. T-joints are used during laying. The joints are bonded with additive-coated clay mortar during installation. Excess mortar on the surface is removed. This top layer must dry again for 24 hours. Then, depending on the surface quality requirements, the resulting floor surface is coated with additive-coated clay putty. Before applying the putty, the surface of the laid clay modules must be rinsed with water again. After the leveling material dries, approximately 24 hours later, the surface can be treated or shaped as needed. If the surface is to remain visible, it must be protected from moisture. This can be achieved using carnauba wax. If, for example, you choose composite or parquet flooring, the impact insulation layer and floor cover can be laid directly on the untreated surface of the clay putty.

[0086] The thickness of clay underfloor heating systems can be selected in 30mm increments based on the structure (floating, composite) and required height. The minimum thickness is two layers (60mm): one for guiding the heating pipes and one for heat distribution. The maximum thickness is limited by static conditions. The flexural tensile strength can be 3.32 N / mm². 2 The compressive strength can be 3.31 N / mm². 2 .

[0087] The advantage of the clay building material according to the present invention lies in the fact that, through the use of additives, an additive is formed that can actively modify the properties of the clay building material for use, particularly in the installation of underfloor heating systems. Depending on the amount of each component, parameters such as tensile / compressive / flexural tensile / shear strength, flowability, adhesive strength, and foaming properties can be produced. The additives used are biodegradable and durable.

[0088] Reuse / Recycling / Disposal The clay material containing additives to be recycled (such as clay mortar containing additives) is crushed and soaked in water. Warm water accelerates the soaking process. A calculated amount of vinegar must be added to the water to prevent mold formation, as the vinegar has already degraded during the initial processing. The softened material can then be incorporated into the production process. Depending on the purity of the recycled material, it can almost regain its initial strength. However, it must be retested before use.

[0089] If clay building materials produced from or in conjunction with composite clay materials require disposal, they can be returned to nature. Environmental factors such as rainfall, as well as naturally occurring microorganisms and molds, will convert the additives (in the case of purely organic additives) into nitrogen that can be used by plants.

[0090] Other advantages and advantageous embodiments of the invention will become apparent from the following description of the drawings, figures, and claims. Attached Figure Description

[0091] The embodiments of the solution of the present invention will be explained in detail below with reference to the accompanying schematic diagrams. The diagrams are as follows: Figure 1 A longitudinal sectional view of a three-layer clay floor heating system is shown. Figure 2 A longitudinal sectional view of a two-layer clay floor heating system is shown. Figure 3 A top view of the clay module layer is shown. Figure 4 This shows a top view of clay module layers used for two- or three-layer clay underfloor heating. Figure 5 A top view of a clay module layer with heating pipes is shown, and Figure 6 A top view of a clay module layer with a smoothed surface is shown. Detailed Implementation

[0092] Figure 1The use of clay building material 100 for clay underfloor heating 10 is shown, in this embodiment being a three-layer clay underfloor heating 12. To stabilize, improve flowability, or foam the clay building material 100, additives including bone glue particles, vinegar (25%), and water are added. The three-layer clay underfloor heating 12 has a floating structure. A three-layer clay module 14 is formed. To create the clay underfloor heating 10, i.e., underfloor heating in a clay leveling layer, clay mortar 18 with additives and precast components are prepared. The clay module 14 is used. The additives may specifically include bone glue particles, vinegar (25%), and water. In this embodiment, 7.5 kg of 0 / 8 rammed earth is used to create the clay module 14, which is mixed with the water proportion specified by the manufacturer and introduced into a steel mold with internal dimensions of width x length x height = 300 x 400 x 100 mm. The rammed earth mixture is processed without additives. The rammed earth mixture is pressed in the steel mold using a suitable press at 13.33 N / mm. 2 Press, demold, and then dry on a suitable support. To prevent warping, the support surface must be as small as possible during drying. The pressed clay module 14 has dimensions of length x width x height = 400 x 300 x 27 mm. The dried clay module 14 can be stacked and stored on a standard European pallet.

[0093] The surface is formed by clay putty 16 with additives. Clay mortar 18 with additives is formed between two clay modules 14. Heating pipes 20 are arranged in this clay mortar 18. One clay module 14 is placed on clay compensating material 22, which also contains additives. A seal 24 and insulation 26 are provided on the underside facing the floor. To obtain insulation 26 formed as clay insulation, the amount of additives (especially vinegar) can be increased and the amount of water added can be reduced, thus producing a clay foaming effect. The foaming process can be enhanced if caustic soda is added to the clay raw material as needed. In this case, caustic soda is mixed into the clay building material 100, and then the additives are added only briefly before processing. Thus, depending on the amount of vinegar and caustic soda, the load-bearing capacity and density of the clay are reduced, forming a foam-like structure. From this mixture, insulation boards for insulation 26 can be produced using a mold. These can be used as floor or wall insulation. This embodiment may specifically include 1200g of clay mortar 18, 120g of bone glue granules, 70g of tap water, and 130g of vinegar (25%), as well as 12g of caustic soda. The strength, for example, may be a flexural tensile strength of 5.5 N / mm². 2 and compressive strength 12N / mm 2 .

[0094] Figure 2The use of clay building material 100 for clay underfloor heating 10 is shown in this second embodiment as a two-layer clay underfloor heating system 24. Two layers of clay modules 14 are formed. Clay mortar 18 with additives is arranged between these two layers. Heating pipes 20 are embedded in the clay mortar 18. The upper covering is formed by clay putty 16 with additives. Clay filler material 22 including additives is placed on a concrete floor slab 26.

[0095] For the paving system, clay mortar 18 is used to bond different components together. Clay mortar 18 includes flexible additives. These additives, such as a base mixture, specifically containing 300g clay mortar, 40g bone glue granules, 60g tap water, and 7g vinegar (25%), form an additive that can modify the properties of the clay building material. Depending on the amounts of each component, parameters such as tensile / compressive / flexural tensile / shear strength, flowability, bond strength, and foaming can be produced. The additives used are biodegradable and durable. Stabilizing and foaming additives can be added to clay mortar 18.

[0096] For underfloor heating installation, as illustrated in the example, it begins with clay filler 22. Depending on the structure (floating, composite), the clay filler is applied to the base layer, and a first layer of clay modules 14 is laid on top of the clay filler 22. The installation uses T-joints. The joints are bonded with additive-coated clay mortar 18 during installation. Subsequently, other clay modules 14 are cut to pipe spacing (e.g., 95 x 400 mm). The cut clay modules 14 form a second layer in which heating pipes 30 are laid. Shortly before applying the additive-coated clay mortar 18, a small amount of water is brushed onto the surface of the first layer of clay modules 14 to create a connection between the additive-coated clay mortar 18 and the clay modules 14. The cut clay modules 14 are then laid into the additive-coated clay mortar 18 at pipe spacing 28, and the installation joints of the heating pipes 30 are defined by means of maintaining the spacing (e.g., remaining sections of the heating pipes). Excess additive-coated clay mortar 18 is removed from the laying joints to allow for the standard installation of the heating pipes 30 after drying. If the second layer is fully laid, allow it to dry for 1-2 days, depending on the indoor climate. After drying, introduce the heating pipes 30 (e.g., PE-RT, PE-XE, PE-XC, aluminum-plastic composite pipes) into the newly applied bed of additive-coated clay mortar in the laying joints, and then cover them with additive-coated clay mortar 18. Immediately before applying the additive-coated clay mortar 18, brush a small amount of water onto the surface of the clay modules 14 again to create a bond between the additive-coated clay mortar 18 and the clay modules 14. A third layer consisting of clay modules 14 is then laid over the subsequently applied additive-coated clay mortar 18. The laying uses T-joints. The joints are bonded with additive-coated clay mortar 18 during laying. Excess clay mortar 18 on the surface is removed. This top layer must dry again for 24 hours. Then, depending on the surface quality requirements, apply the resulting floor surface with clay putty 16 containing additives. Before applying the leveling material 16, the surface of the laid clay modules 14 must be brushed with water again. After the leveling material dries, approximately 24 hours later, the surface can be treated or shaped as needed. If the surface is to remain visible, it must be moisture-proof. This can be achieved with carnauba wax. If, for example, composite or parquet flooring is chosen, impact insulation and floor coverings can be laid directly on the untreated surface of the clay filler 16.

[0097] Figure 3A layer of clay module 14 is shown, which is placed in a floating structure within clay filler material 22. The laying pattern of this floating layer of clay module 14 is shown. To improve resistance and adhesion strength, clay mortar 18 and clay putty 16, including additives, are used. Any clay manufacturer's base mortar or clay putty 16 can be used in combination with the developed additives. The increase in strength and adhesion can be controlled by the amount of additive. Performance will vary depending on the manufacturer's base mortar, based on its naturally occurring mixing ratio, and must be determined before each distribution.

[0098] To improve fluidity, clay mortar 18, clay filler, and / or clay leveling agent can be used. For example, any base mortar or clay manufacturer's base mortar or clay putty 18 can be used in combination with additives (increasing the water content). The improvement in fluidity can be controlled by the amount of water. Shrinkage cracking may occur depending on the clay content of the base material. Performance will vary depending on the manufacturer's base material, based on its naturally occurring mixing ratio, and must be determined before each distribution.

[0099] Figure 4 The diagram shows a layer of clay modules 14 cut and placed in clay filler 22 within a composite structure. The clay modules 14 may also be arranged in clay mortar 18, which contains additives. The clay filler 22 dries for approximately 24 hours. Spacing 28 is formed for the heating tubes 30.

[0100] Figure 5 The introduction of heating pipe 30 is shown. The structural thickness of the clay floor heating system can be selected in 30mm increments based on the structure (floating, composite) and the required structural height. The minimum thickness is two layers (60mm): one layer for guiding the heating pipe and one layer for heat distribution. The maximum thickness is limited by static conditions. The flexural tensile strength can be 3.32 N / mm². 2 The compressive strength can be 3.31 N / mm². 2 .

[0101] Figure 6 The clay module 14 is shown in the additive-coated clay mortar 18, which requires 24 hours to dry. The surface is then smoothed with additive-coated clay putty 16.

[0102] The present invention also relates to 1. a clay building material (100) having a clay mortar (18) that can bond different components together for use in a floor heating system in a clay leveling layer, characterized in that the clay building material (100) includes additives, which are flexible and formed by a mixture of additives, thereby changing the properties of the clay building material (100), and according to the changes in the components of the additives, parameters such as tensile strength, compressive strength, flexural tensile strength, shear strength and flowability can be affected by the adhesive force.

[0103] The present invention also relates to 2. the clay building material (100) according to item 1, characterized in that the clay building material (100) includes clay wall mortar, clay plastering mortar, clay putty, clay reinforcing material, clay adhesive, rammed earth, clay bricks, clay boards, clay paperboards, lintels and annular anchors.

[0104] The present invention also relates to 3. the clay building material (100) according to item 1 or 2, characterized in that, for stabilization, improved fluidity or foaming of the clay building material (100), the additive mixture is formed from bone glue particles, 25% by weight of vinegar and water.

[0105] The present invention also relates to 4. a clay building material (100) according to any one of items 1 to 3 above, characterized in that the additive mixture comprises 300g of clay mortar, 40g of bone glue particles, 60g of tap water and 7g of 25% vinegar.

[0106] The present invention also relates to 5. a clay building material (100) according to any one of items 1 to 4 above, characterized in that, in order to produce a heat-insulating device, caustic soda is added to the clay building material (100) and mixed therein with the additive mixture, thereby enhancing the foaming process of the clay building material (100).

[0107] The present invention also relates to 6. the clay building material (100) according to item 5, characterized in that the clay building material (100) comprises 1200g clay mortar, 120g bone glue granules, 70g tap water and 130g 25% vinegar, and 12g sodium carbonate to achieve larger pores, and has a flexural tensile strength of 5.5 N / mm. 2 The compressive strength is 12 N / mm². 2 .

[0108] The present invention also relates to 7. a clay building material (100) according to any one of items 1 to 6, characterized in that the heating pipe is formed of PE-RT, PE-XE, PE-XC or aluminum-plastic composite pipe.

[0109] The present invention also relates to 8. A method for manufacturing a clay building material (100) with a clay leveling layer for underfloor heating according to any one of items 1 to 7, comprising the following steps: a. Prepare precast clay modules (14), through... b. Mix 0 / 8 rammed earth with water. c. Pour into the mold d. Pressing in a mold e. Drying f. Apply the clay filler material (22) to the base course. g. Lay the first layer of clay module (14) on the clay compensating material (22). h. Preparation of clay mortar including additives (18), and i. Use clay mortar (18) to bond the joints. j. A composite of clay module (14) and clay mortar with additives (18) is prepared by applying water to the surface of the first layer. k. Cut the other clay modules (14) into tube spacings. l. Form the second layer using the cut clay modules (14). m. drying n. Introduce the heating pipe into the newly applied clay mortar (18) bed with additives in the laying joint. o. Cover with clay mortar with additives.

[0110] The present invention also relates to 9. the method according to item 8, characterized in that, after step o), after the surface drying stage of the second layer, and after subsequently brushing the surface of the clay module (14) with water and applying another layer of clay mortar with additives (18), at least one other layer is applied.

[0111] The present invention also relates to 10. the method according to item 8 and / or 9, characterized in that, as a further method step, the resulting floor surface is coated with clay putty (16) with additives according to surface quality requirements, wherein the surface of the laid clay module (14) is brushed with water again before the leveling material of the clay putty (16) is applied, and the surface is treated or shaped after the leveling material dries.

[0112] The present invention also relates to 11. the method according to item 10, characterized in that the surface is kept visible by applying carnauba wax to protect it from moisture.

[0113] The present invention also relates to 12. the method according to item 10, characterized in that, when the floor cover layer is subsequently laid to form a composite floor or parquet floor, the impact sound insulation layer and the floor cover layer are laid directly on the untreated surface of the clay putty (16).

[0114] The present invention also relates to 13. the method according to any one of items 8 to 12, characterized in that, in order to prepare the clay module (14), 7.5 kg of 0 / 8 rammed earth is used, which is mixed with a suitable water ratio and introduced into a mold designed as a steel mold with internal dimensions of width x length x height = 300 x 400 x 100 mm, wherein the rammed earth mixture is processed without additives, and the rammed earth mixture is pressed in the steel mold by a suitable press at 13.33 N / mm. 2Press, demold, and then dry on a suitable support. To avoid warping of the clay module (14), the support surface of the clay module (14) is kept as small as possible during drying, wherein the dimensions of the pressed clay module (14) are length x width x height = 400 x 300 x 27 mm.

[0115] The present invention also relates to 14. the method according to any one of items 8 to 13, characterized in that the joint in step i) is formed as a T-shaped joint, and the T-shaped joint is bonded with clay mortar (18) with additives during laying, and then excess clay mortar (18) on the surface is removed.

[0116] The present invention also relates to 15. the method according to any one of items 8 to 14, characterized in that the clay compensating material (22) is formed and applied to the corresponding base layer in a floating manner or as a composite.

[0117] All features shown in the specification, the following claims, and the accompanying drawings are important to the invention, either individually or in any combination thereof.

[0118] List of reference numerals in the attached diagram: 10- Clay floor heating 12-Three-layer clay floor heating 14-Clay Module 16-Clay Putty 18-Clay Mortar 20-Heating element 22-Clay Compensation Material 24-Two-layer clay floor heating 26-Concrete floor slab 28- Heating tube spacing 30-Heating tube 100 - Clay building materials.

Claims

1. A composite clay material having at least 35% by weight of clay and additives, the additives having a gelatinous content and / or a gelling agent content and an acid content.

2. The composite clay material according to claim 1, characterized in that, The additive contains at least one organic acid and / or inorganic acid.

3. The composite clay material according to claim 2, characterized in that, The organic acid is acetic acid, formic acid, lactic acid, tartaric acid, malic acid, or citric acid, and the inorganic acid is hydrochloric acid, sulfuric acid, or nitric acid.

4. The composite clay material according to any one of the preceding claims, characterized in that, The additive contains water.

5. The composite clay material according to any one of the preceding claims, characterized in that, The additive contains sodium carbonate and / or sodium bicarbonate as pore-forming agents.

6. The composite clay material according to claims 2, 3 and 5, characterized in that, The additive contains 3% to 75% by weight of gelatin and / or gelling agent, 0.1% to 97% by weight of organic and / or inorganic acid, 0% to 97% by weight of water and 0% to 40% by weight of sodium carbonate and / or sodium bicarbonate, totaling 100% by weight.

7. The composite clay material according to any one of the preceding claims, characterized in that, The gelling agent is composed of alginate, sodium alginate, potassium alginate, ammonium alginate, calcium alginate, agar, carrageenan, locust bean gum, guar bean gum, tragacanth gum, xanthan gum, tara gum, gellan gum, pectin, cellulose powder, gelatin and / or modified starch.

8. The composite clay material according to any one of the preceding claims, characterized in that, It contains plant fibers, especially wood fiber, straw, hemp fiber, jute, sisal and / or flax.

9. The composite clay material according to any one of the preceding claims, characterized in that, It is provided as a processable mixture.

10. Use of a composite clay material according to any one of the preceding claims for manufacturing clay building materials, particularly clay bricks, clay plaster, clay mortar, clay putty, clay reinforcing material, clay leveling material, clay coating, clay compensating material, clay adhesive, clay board, clay cardboard, lintels, ring anchors, or rammed earth.

11. A method for manufacturing clay building materials using the composite clay material according to any one of claims 1 to 9, characterized in that, Water and heat are supplied to the composite clay material until the mixture reaches a viscosity greater than 100 mPas, and the mixture is then shaped as desired and dried.

12. The method according to claim 11, characterized in that, The mixture is given the desired shape by molding or extrusion or by multiple layer-by-layer application and drying.

13. The method according to claim 11 or 12, characterized in that, Plant fibers and / or fabrics are introduced into the mixture.

14. An additive for manufacturing a composite clay material according to any one of claims 1 to 9, characterized in that, The additive contains 3% to 75% by weight of gelatin and / or gelling agent, 0.1% to 97% by weight of organic and / or inorganic acid, 0% to 97% by weight of water and 0% to 40% by weight of sodium carbonate and / or sodium bicarbonate, totaling 100% by weight.

15. The additive according to claim 14, characterized in that, The water content is so low that the additive is in powder form.

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