A high alkali-resistant and corrosion-resistant composite brick

Abstract

A high alkali-resistant and corrosion-resistant composite brick, relating to the field of composite brick technology, includes a matrix layer, an alkali-resistant intermediate layer, and a corrosion-resistant surface layer. The matrix layer uses high-alumina cement as the base material, incorporating silica fume and fly ash, and provides basic support. The alkali-resistant intermediate layer is located above the matrix layer and is composed of alkali-resistant glass fiber mesh and silane coupling agent modified epoxy resin. The alkali-resistant intermediate layer forms a physical barrier, blocking the diffusion path of alkali ions. The corrosion-resistant surface layer is located above the alkali-resistant intermediate layer and is composed of a ceramic particle layer and a glass flake coating. The corrosion-resistant surface layer directly contacts the corrosive medium and resists chemical erosion through hard particles and a low-permeability coating, achieving high-efficiency resistance to corrosive media such as acids and alkalis, significantly improving the durability and service life of the brick, thereby meeting the stringent requirements of construction projects in highly corrosive environments.

Description

Technical Field

[0001] This utility model relates to the field of composite brick technology, specifically a high alkali-resistant and corrosion-resistant composite brick. Background Technology

[0002] In modern industrial sectors such as chemical engineering, environmental protection, and metallurgy, infrastructure is constantly exposed to the corrosive effects of acids and alkalis. Currently, traditional building materials such as ordinary clay bricks, concrete bricks, and conventional acid-resistant bricks are widely used in these applications. Ordinary clay bricks and concrete bricks contain numerous pores and capillary channels, while conventional acid-resistant bricks primarily rely on their surface glaze or internal acid-resistant mineral components for protection.

[0003] For example, the Chinese authorized patent CN204027328U, entitled "A Novel Acid-Resistant Brick," includes a rectangular brick body with grooves on each of its four sides, and adjacent grooves are interconnected. Before the protected substrate comes into contact with corrosive media, the novel acid-resistant brick's anti-corrosion structure more effectively blocks the penetrating and seeping corrosion of the protected substrate. This results in an anti-corrosion structure formed on the surface of the novel acid-resistant brick that not only leverages the strong individual anti-corrosion properties of the acid-resistant (or acid- and temperature-resistant) brick, but also provides a more effective synergistic effect in terms of overall barrier and anti-corrosion performance.

[0004] In alkaline environments, the aforementioned existing technologies allow alkaline media to penetrate the brick's interior through pores, triggering an alkali-aggregate reaction. This causes the brick to expand, crack, and experience a significant decrease in strength, seriously threatening the structural safety of buildings. Conventional acid-resistant bricks, in alkaline environments, fail to form an effective barrier due to the inability of their protective components to do so. The surface glaze easily peels off, and the internal materials are corroded, requiring frequent repairs and replacements, resulting in high maintenance costs and disruptions to project operation. Furthermore, existing single-material corrosion-resistant bricks lack the synergistic corrosion resistance of chemical protection and physical barriers. Traditional bricks have simple interlayer bonding methods, making them prone to interlayer separation and delamination under temperature changes and mechanical stress, weakening corrosion resistance and structural stability. Therefore, they do not meet current requirements. To address these issues, we propose a high-alkali-resistant and corrosion-resistant composite brick. Utility Model Content

[0005] The purpose of this invention is to provide a high alkali-resistant and corrosion-resistant composite brick. Through multi-layer composite structure design and optimized material combination, it achieves high resistance to corrosive media such as acids and alkalis, significantly improves the durability and service life of the brick, and thus meets the stringent requirements of building engineering in highly corrosive environments.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a high alkali-resistant and corrosion-resistant composite brick, comprising a matrix layer, an alkali-resistant intermediate layer, and a corrosion-resistant surface layer. The matrix layer uses high-alumina cement as the base material, incorporating silica fume and fly ash, and serves to provide basic support. The alkali-resistant intermediate layer is located above the matrix layer and is composed of alkali-resistant glass fiber mesh and silane coupling agent modified epoxy resin. The alkali-resistant intermediate layer forms a physical barrier, blocking the diffusion path of alkali ions. The corrosion-resistant surface layer is located above the alkali-resistant intermediate layer and is composed of a ceramic particle layer and a glass flake coating. The corrosion-resistant surface layer directly contacts the corrosive medium and resists chemical erosion through hard particles and a low-permeability coating.

[0007] Preferably, spherical closed-pore ceramic microspheres are introduced into the matrix layer to form a closed pore structure.

[0008] Preferably, the silane coupling agent modified epoxy resin is impregnated and wrapped around the outside of the alkali-resistant glass fiber mesh.

[0009] Preferably, the ceramic particle layer is formed by mixing and pressing silicon carbide particles with furan resin, and the glass flake coating is composed of corrosion-resistant vinyl ester resin and glass flakes, and the glass flake coating is applied to the upper surface of the ceramic particle layer.

[0010] Preferably, the upper and lower end faces of the alkali-resistant intermediate layer are provided with a plurality of protrusions in a rectangular array, the upper end face of the substrate layer is provided with a plurality of first grooves, and the lower end face of the corrosion-resistant surface layer is provided with a plurality of second grooves, and the protrusions are respectively inserted into and engaged with the first grooves and the second grooves.

[0011] Preferably, a flexible transition layer formed by silicone-acrylic emulsion is provided between the bonding surfaces of the substrate layer, the alkali-resistant intermediate layer, and the corrosion-resistant surface layer.

[0012] Preferably, the thickness of the substrate layer is 18-25 mm, the thickness of the alkali-resistant intermediate layer is 4-8 mm, and the total thickness of the corrosion-resistant surface layer is 3-5 mm.

[0013] Compared with the prior art, the beneficial effects of this utility model are:

[0014] 1. This utility model achieves multi-dimensional resistance to acids, alkalis and corrosive media through multi-layer structural design and material combination. The alkaline environment of the base layer and the physical and chemical dual protection mechanism of the alkali-resistant intermediate layer effectively block the intrusion of alkaline media. The high-hardness ceramic particles and low-permeability glass flake coating of the corrosion-resistant surface layer can strongly resist various chemical erosions and significantly improve the durability of composite bricks in strong corrosive environments.

[0015] 2. The closed-pore structure formed by the closed-cell ceramic microspheres in the matrix layer of this utility model significantly reduces the water absorption rate of the composite brick, effectively preventing structural deterioration caused by water intrusion. The flexible transition layer of silicone-acrylic emulsion can alleviate the stress caused by thermal expansion and contraction. The mortise and tenon structure enhances the mechanical interlocking between layers, making each layer tightly bonded, and ensuring that the composite brick maintains good mechanical properties and structural integrity during long-term use.

[0016] 3. This utility model adopts a multi-layer composite structure, organically combining chemical protection and physical barrier. Each layer of material performs its own function and works synergistically to give full play to the advantages of different materials, effectively solving the problem of insufficient durability of traditional bricks in highly corrosive environments. Attached Figure Description

[0017] Figure 1 This is an exploded view of the present invention;

[0018] Figure 2 This is a perspective view of the present utility model;

[0019] Figure 3 This is a schematic diagram of the internal structure of the present invention;

[0020] Figure 4 for Figure 3 Enlarged view of the structure at point A.

[0021] In the figure: 1. Substrate layer; 11. First groove; 2. Alkali-resistant intermediate layer; 21. Alkali-resistant glass fiber mesh; 22. Silane coupling agent modified epoxy resin; 23. Protrusion; 3. Corrosion-resistant surface layer; 31. Ceramic particle layer; 32. Glass flake coating; 33. Second groove; 4. Flexible transition layer. Detailed Implementation

[0022] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0023] Please see Figure 1-4 The present invention provides an embodiment of a high alkali-resistant and corrosion-resistant composite brick, comprising a matrix layer 1, an alkali-resistant intermediate layer 2, and a corrosion-resistant surface layer 3. The thickness of the matrix layer 1 is 18-25 mm, the thickness of the alkali-resistant intermediate layer is 4-8 mm, and the total thickness of the corrosion-resistant surface layer is 3-5 mm. The matrix layer 1 uses high-alumina cement as the base material and incorporates silica fume and fly ash. The matrix layer 1 is used to provide basic support. Spherical closed-cell ceramic microspheres are introduced into the matrix layer 1 to form a closed pore structure.

[0024] The alkaline environment of high-alumina cement itself can neutralize external alkaline media. Silica powder and fly ash fill the pores, increasing density. The closed-pore structure formed by spherical closed-cell ceramic microspheres in matrix layer 1 effectively prevents moisture and alkaline substances from penetrating into the brick body. This not only enhances the initial strength and overall stability of the composite brick but also significantly reduces water absorption, minimizing structural degradation caused by moisture and alkaline intrusion, extending the service life of the composite brick, and providing a stable supporting foundation for the upper structure.

[0025] Please see Figure 1 and Figure 3 The alkali-resistant intermediate layer 2 is located above the matrix layer 1, and the alkali-resistant intermediate layer 2 is composed of alkali-resistant glass fiber mesh 21 and silane coupling agent modified epoxy resin 22. The alkali-resistant intermediate layer 2 forms a physical barrier to block the diffusion path of alkali ions. The silane coupling agent modified epoxy resin 22 is impregnated and wrapped around the outside of the alkali-resistant glass fiber mesh 21.

[0026] Alkali-resistant glass fiber mesh 21 forms a dense physical barrier layer, blocking the diffusion of alkali ions. Silane coupling agent-modified epoxy resin 22 reacts chemically with alkaline substances through chemical bonding, adsorbing and fixing them. Simultaneously, the epoxy resin impregnation of the mesh further fills the gaps in the mesh, enhancing the physical barrier effect of the alkali-resistant intermediate layer 2. This synergistic approach of physical barrier and chemical adsorption resists alkaline erosion, significantly improving the alkali resistance of the composite brick and ensuring its structural integrity in alkaline environments.

[0027] Please see Figure 1 and Figure 3 The corrosion-resistant surface layer 3 is located above the alkali-resistant intermediate layer 2. The corrosion-resistant surface layer 3 is composed of a ceramic particle layer 31 and a glass flake coating 32. The corrosion-resistant surface layer 3 is in direct contact with the corrosive medium and resists chemical erosion through hard particles and a low-permeability coating. The ceramic particle layer 31 is made by mixing and pressing silicon carbide particles with furan resin. The glass flake coating 32 is composed of corrosion-resistant vinyl ester resin and glass flakes, and the glass flake coating 32 is coated on the upper surface of the ceramic particle layer 31.

[0028] Silicon carbide particles possess high hardness, enabling them to resist mechanical erosion and wear from corrosive media. Furan resin, with its excellent resistance to strong acids and alkalis, encapsulates the silicon carbide particles to form a corrosion-resistant whole. In the glass flake coating 32, the glass flakes are arranged parallel to the brick surface, forming a labyrinthine impermeable structure that significantly extends the penetration path of corrosive media. Vinyl ester resin provides good adhesion and corrosion resistance. This effectively resists the erosion of various strong acids and alkalis, reducing corrosion loss on the composite brick surface and improving the durability and protective performance of the composite brick in highly corrosive environments.

[0029] Please see Figure 1 , Figure 3 and Figure 4 The upper and lower end faces of the alkali-resistant intermediate layer 2 are provided with a rectangular array of multiple protrusions 23, the upper end face of the substrate layer 1 is provided with multiple first grooves 11, and the lower end face of the corrosion-resistant surface layer 3 is provided with multiple second grooves 33, and the protrusions 23 are respectively inserted into the first grooves 11 and the second grooves 33.

[0030] The anti-alkali intermediate layer 2's protrusions 23 interlock with the first groove 11 of the base layer 1 and the second groove 33 of the corrosion-resistant surface layer 3, forming a mechanical interlocking structure. Relying on friction and the mechanical action of mutual interlocking, the layers are tightly connected together. This enhances the connection strength and stability between the composite brick layers, effectively preventing interlayer peeling and detachment. It allows the composite brick to maintain the integrity of its overall structure even under external forces or environmental changes, improving its mechanical properties and service life.

[0031] Please see Figure 4 A flexible transition layer 4, formed by silicone-acrylic emulsion, is provided between the bonding surfaces of the base layer 1, the alkali-resistant intermediate layer 2, and the corrosion-resistant surface layer 3. After the silicone-acrylic emulsion cures, it forms an elastic flexible transition layer 4. When the composite brick expands and contracts due to temperature changes, the flexible transition layer 4 can absorb and buffer the stress generated between the layers through its own elastic deformation. This avoids cracks or separation between the layers of the composite brick due to thermal stress concentration, enhances the adaptability and structural stability of the composite brick under different temperature environments, and further extends the service life of the composite brick.

[0032] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A high-alkali-resistant and corrosion-resistant composite brick, comprising a base layer (1), an alkali-resistant intermediate layer (2) and a corrosion-resistant surface layer (3), characterized in that: The substrate layer (1) is based on high-alumina cement and mixed with silica fume and fly ash. The substrate layer (1) is used to provide basic support. The alkali-resistant intermediate layer (2) is located above the substrate layer (1). The alkali-resistant intermediate layer (2) is composed of alkali-resistant glass fiber mesh (21) and silane coupling agent modified epoxy resin (22). The alkali-resistant intermediate layer (2) forms a physical barrier to block the diffusion path of alkali ions. The corrosion-resistant surface layer (3) is located above the alkali-resistant intermediate layer (2). The corrosion-resistant surface layer (3) is composed of ceramic particle layer (31) and glass flake coating (32). The corrosion-resistant surface layer (3) is in direct contact with the corrosive medium and resists chemical erosion through hard particles and low permeability coating.

2. The high alkali resistance and corrosion resistance composite brick according to claim 1, characterized in that: Spherical closed-pore ceramic microspheres are introduced into the matrix layer (1) to form a closed pore structure.

3. The high alkali resistant corrosion resistant composite brick according to claim 1, characterized in that: The silane coupling agent modified epoxy resin (22) is impregnated and wrapped around the outside of the alkali-resistant glass fiber mesh (21).

4. The high alkali resistant corrosion resistant composite brick according to claim 1, characterized in that: The ceramic particle layer (31) is formed by mixing and pressing silicon carbide particles with furan resin, and the glass flake coating (32) is composed of corrosion-resistant vinyl ester resin and glass flakes, and the glass flake coating (32) is coated on the upper surface of the ceramic particle layer (31).

5. The high alkali resistant corrosion resistant composite brick according to claim 1, characterized in that: The upper and lower end faces of the alkali-resistant intermediate layer (2) are provided with a rectangular array of multiple protrusions (23), the upper end face of the substrate layer (1) is provided with multiple first grooves (11), and the lower end face of the corrosion-resistant surface layer (3) is provided with multiple second grooves (33), and the protrusions (23) are respectively inserted into the first grooves (11) and the second grooves (33).

6. The high alkali resistant corrosion resistant composite brick according to claim 5, characterized in that: A flexible transition layer (4) formed by silicone acrylic emulsion is provided between the bonding surfaces of the substrate layer (1), the alkali-resistant intermediate layer (2) and the corrosion-resistant surface layer (3).

7. The high alkali resistant corrosion resistant composite brick according to claim 1, characterized in that: The thickness of the substrate layer (1) is 18-25 mm, the thickness of the alkali-resistant intermediate layer (2) is 4-8 mm, and the total thickness of the corrosion-resistant surface layer (3) is 3-5 mm.

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