Bricks and their manufacturing method

Abstract

The present invention relates to a brick and a manufacturing method thereof, and provides a brick and a manufacturing method thereof, which uses soil (e.g., loess, clay, kaolin, and / or dredged soil) or sludge as a base material for the brick, and includes a solidifying agent to solidify the base material, thereby improving at least the strength of the brick. According to the present invention, the particles of the base material that make up the brick are firmly bound using the solidifying agent, thereby improving at least the strength of the brick.

Description

[Technical Field]

[0001] The present invention relates to a brick and a manufacturing method thereof, and more particularly to a brick that uses soil (e.g., loess, clay, kaolin, and / or dredged soil) or sludge as a base material, and includes a solidifying agent that solidifies the base material, thereby having at least improved strength, a manufacturing method thereof, and a brick manufacturing apparatus that can manufacture high-strength bricks through a continuous extrusion process. [Background technology]

[0002] Bricks are widely used in the construction of building walls. Firebricks are used in the construction of boilers, blast furnaces, electric furnaces, and nuclear reactors. Generally, bricks are made from sand, cement, and earth (e.g., loess, clay, kaolin), etc. Recently, earth bricks, which are primarily composed of loess and clay, have become more popular.

[0003] Furthermore, from the perspective of resource recycling, technologies have been proposed that use sludge, dredged soil, and other materials as brick materials. For example, Korean Patent No. 10-0949932 proposes a method for manufacturing lightweight bricks using sludge generated in sewage / wastewater facilities, and Korean Patent No. 10-1002547 proposes clay bricks made from recycled dredged soil and sludge, and a manufacturing method for the same. However, conventional earth bricks (loess, clay) and recycled bricks (sludge, dredged soil) have the problem of weak adhesion between the material particles that make up the bricks, resulting in reduced strength.

[0004] On the other hand, bricks can be divided into pressurized and extruded types depending on their manufacturing method.

[0005] The pressurized method involves inserting brick material into a mold of a specific shape and size and applying pressure (pressing) using a hydraulic press. The pressurized method can produce bricks with high strength (such as compressive strength), but has lower productivity than the extrusion method. For example, Korean Patent No. 10-1302069 and Korean Utility Model No. 20-0228809 disclose brick manufacturing devices related to the pressurized method.

[0006] The extrusion method involves injecting brick material into an extruder (also known as a "kneader") and continuously extruding and cutting it to a specific size. Because it is a continuous process, the extrusion method offers the advantage of higher productivity compared to the pressurized method. Specifically, the extrusion method involves injecting viscous brick material (e.g., dough such as loess or clay) into an extruder equipped with a feed screw, forcing the material through a specific-shaped extrusion section (or mold) by driving the feed screw, extruding the material, and then cutting it with a cutter to continuously produce bricks of a specific shape. In this case, the extrusion section (or mold) is smaller than the extruder body, and the shape and size (thickness and width) of the bricks are determined by the specifications of the extrusion section (or mold). For example, Korean Patent Nos. 10-0298634, 10-1131687, and 10-1743180 disclose brick manufacturing devices related to the extrusion method.

[0007] However, while the conventional extrusion brick manufacturing method offers higher productivity than the pressurized method, it has the drawback of producing bricks with low texture density (the density of raw material particles). This results in weak brick strength and, in some cases, distortion during the drying process.

[0008] Depending on the purpose and application of the bricks, larger bricks than the general standard may be required, but in the past, the size of the bricks was determined (limited) by the inner diameter (standard) of the extrusion part (or mold). In other words, with the conventional brick manufacturing technology, it was difficult to significantly increase the inner diameter of the extrusion part (or mold), and the size of the bricks (width or thickness) was limited to the inner diameter of the extrusion part (or mold). [Prior art documents] [Patent documents]

[0009] [Patent Document 1] Korean Patent No. 10-0949932 [Patent Document 2] Korean Patent No. 10-1002547 [Patent Document 3] Korean Patent No. 10-1302069 [Patent Document 4] Korean Utility Model No. 20-0228809 [Patent Document 5] Korean Patent No. 10-0298634 [Patent Document 6] Korean Patent No. 10-1131687 [Patent Document 7] Korean Patent No. 10-1743180 Summary of the Invention [Problem to be solved by the invention]

[0010] SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a brick in which the material particles constituting the brick are firmly bonded together, thereby at least providing improved strength, and a method for manufacturing the same.

[0011] Another object of the present invention is to provide a brick manufacturing method and a brick manufacturing apparatus that can manufacture bricks by a continuous extrusion process and that can manufacture high-strength (high-density) bricks with a high-density structure.

[0012] Furthermore, an object of the present invention is to provide a brick manufacturing method and a brick manufacturing apparatus that can manufacture bricks that have a dense structure but are larger than the inner diameter (standard) of the extrusion part. [Means for solving the problem]

[0013] To achieve the above object, the present invention provides a brick comprising a base material and a hardening agent for hardening the base material.

[0014] The present invention also provides a brick manufacturing method, which includes the steps of mixing brick materials and molding the mixed brick materials, wherein the brick materials include a base material and a hardening agent that hardens the base material.

[0015] The present invention further provides a method for manufacturing bricks, comprising the steps of mixing brick materials, extruding the mixed brick materials to form a molded body, and cutting the molded body, wherein the brick materials include a base material and a hardening agent that hardens the base material.

[0016] According to an embodiment of the present invention, the solidifying agent includes sodium silicate (Na2SiO3), sodium chloride (NaCl), potassium chloride (KCl), calcium chloride (CaCl2), sodium sulfate (Na2SO4), and citric acid.

[0017] According to an embodiment of the present invention, the base material may include one or more of soil and sludge, and the soil may include loess, clay, kaolin, dredged soil, etc.

[0018] Furthermore, the present invention provides a brick manufacturing apparatus including an extruder that extrudes brick material and includes an extruder body provided with a feed screw and an extrusion section formed on one side of the extruder body; a mold that receives the extrudate from the extrusion section and forms it into a molded body; loading means that applies a load to the extrudate supplied from the extrusion section to the mold to increase the density of the extrudate; and a cutter that cuts the molded body discharged from the mold.

[0019] According to an embodiment of the present invention, the mold includes an expansion mold that forms a molded body having a larger cross section (cross section perpendicular to the extrusion direction) than the extrudate extruded from the extrusion section. In this case, the expansion mold includes an expansion section connected to the extrusion section, and an expansion molding section formed on one side of the expansion section that forms a molded body having a larger cross section (cross section perpendicular to the extrusion direction) than the extrudate.

[0020] According to an embodiment of the present invention, the loading means includes a baffle plate to which the extrudate is closely attached, and a loading member that supports the baffle plate and applies a load. According to another embodiment of the present invention, the loading means may further include a lifting member that moves the loading member up and down. [Effects of the Invention]

[0021] According to the present invention, the particles of the base material constituting the brick are firmly bound together by the solidifying agent, thereby improving at least its strength. Furthermore, according to the present invention, bricks can be produced by a continuous extrusion process, and high-strength (high-density) bricks with a dense structure can be produced. Furthermore, according to the present invention, bricks with a larger size than the extruded portion can be produced by a continuous extrusion process, while still having a dense structure. [Brief explanation of the drawings]

[0022] [Figure 1] FIG. 1 is a side view of a brick manufacturing apparatus according to an embodiment of the present invention. [Figure 2] FIG. 2 is a side view showing the main components of a brick manufacturing apparatus according to an embodiment of the present invention. [Figure 3] FIG. 3 is a plan view showing the main components of a brick manufacturing apparatus according to an embodiment of the present invention. [Figure 4] FIG. 4 is a side view showing the main components of a brick manufacturing apparatus according to an embodiment of the present invention, illustrating the operation process of the brick manufacturing apparatus (in a state where a loading means is provided on the molding line). [Figure 5] FIG. 5 is a side view showing the main parts of a brick manufacturing apparatus according to an embodiment of the present invention, and is a diagram for explaining the operation process of the brick manufacturing apparatus (in a state where the loading means is removed from the molding line). [Figure 6] FIG. 6 is a plan view showing the main part of a brick manufacturing apparatus according to an embodiment of the present invention, in which a loading means is provided. [Figure 7] FIG. 7 shows a comparative example for comparison with the present invention, and is a plan view showing the configuration without a loading means. DETAILED DESCRIPTION OF THE INVENTION

[0023] In the present invention, the term "and / or" is used to include at least one of the preceding and following elements. In the present invention, the terms "first," "second," "one side," and "the other side" are used to distinguish one element from another, and each element is not limited by these terms.

[0024] According to a first embodiment, the present invention provides a high-strength brick having at least improved strength, in which material particles constituting the brick are firmly bound by a hardening agent. According to a second embodiment, the present invention provides a brick manufacturing method for manufacturing high-strength bricks. According to a third embodiment, the present invention provides a brick manufacturing apparatus for manufacturing high-strength bricks, which manufactures bricks having a dense structure (high strength / high density) in an extrusion-type continuous process. According to a fourth embodiment, the present invention provides a brick manufactured using the brick manufacturing apparatus of the present invention. Furthermore, according to a fifth embodiment, the present invention provides a brick manufacturing method using the brick manufacturing apparatus of the present invention, and provides bricks manufactured through the method.

[0025] The brick according to the present invention comprises a base material and a hardening agent for hardening the base material. That is, the brick according to the present invention comprises, as effective brick materials constituting the brick, the base material (main component) and a hardening agent (additional component) for hardening the base material (main component). The brick according to the present invention can be manufactured by, for example, a pressurized method (injection molding) and / or an extrusion method (extrusion molding), without any particular limitation.

[0026] The brick according to the present invention may be a molded product containing a base material and a hardener as active ingredients. In the present invention, the dimensions (width x thickness x length) and shape of the brick are not particularly limited, and the brick according to the present invention may have various sizes, shapes, etc. The brick according to the present invention may have the same dimensions and / or shape as a regular brick. Furthermore, the brick according to the present invention may include a block larger than a regular brick, a panel or board that is slightly flatter and has a larger area (length x width) than a regular brick, and a bar that is longer than a regular brick.

[0027] A method for manufacturing bricks according to the present invention, according to a first embodiment of the present invention, includes a mixing step of mixing brick materials and a step of molding the mixed brick materials. Here, the molding in the molding step can be selected from, for example, pressure molding (injection molding) and / or extrusion molding. A method for manufacturing bricks according to a second embodiment of the present invention, includes a mixing step of mixing brick materials, a step of extruding the mixed brick materials to form a molded body, and a cutting step of cutting the molded body. In the manufacturing method of the present invention, the brick material includes a base material and a hardening agent that hardens the base material.

[0028] Hereinafter, an embodiment of a brick manufacturing apparatus according to the present invention will be described with reference to the accompanying drawings, along with an embodiment of a brick according to the present invention and an embodiment of a brick manufacturing method according to the present invention. The accompanying drawings show exemplary embodiments of the present invention and are provided for understanding the present invention. In the accompanying drawings, thickness may be exaggerated to clearly depict each layer and region, and the scope of the present invention is not limited to the thickness, size, and ratio shown in the drawings. Furthermore, when describing the embodiments of the present invention, detailed description of known general functions and / or configurations will be omitted.

[0029] Fig. 1 is a side view of a brick manufacturing apparatus according to an embodiment of the present invention, Fig. 2 is a side view of the main parts of the brick manufacturing apparatus according to an embodiment of the present invention, and Fig. 3 is a plan view of the main parts of the brick manufacturing apparatus according to an embodiment of the present invention. Figs. 4 and 5 are side views of the main parts of the brick manufacturing apparatus according to an embodiment of the present invention, and are diagrams for explaining the operation process of the brick manufacturing apparatus. Fig. 6 is a plan view of the main parts of the brick manufacturing apparatus according to an embodiment of the present invention, showing a state in which loading means is provided. Fig. 7 is a plan view of the comparative example for comparison with the present invention (Fig. 6), showing a case in which loading means is not provided.

[0030] According to one embodiment, the brick manufacturing apparatus of the present invention includes an extruder 100 that extrudes brick material into a mold 200, a mold 200 that receives the extrudate (P) extruded from the extruder 100 and forms it into a molded body (F), a loading means 300 that applies a load to the extrudate (P) supplied from the extrusion section 160 to the mold 200 to increase the density of the extrudate (P), and a cutter 400 that cuts the molded body (F) discharged from the mold 200. According to another embodiment, the brick manufacturing apparatus of the present invention may further include a mixer 20 (e.g., a water-mixing mixer) for mixing the brick material and / or a feed conveyor 30 for transporting the molded body (F). Examples of each component are shown below.

[0031] First, in the present invention, the brick material includes a base material and a hardening agent.

[0032] The base material that can be used as the material for the bricks is not particularly limited. The base material can be selected from various materials such as sand, cement, soil, and sludge. According to an embodiment of the present invention, the base material can include one or more selected from soil and sludge. The soil can be selected from, for example, loess, clay, kaolin, and dredged soil. Furthermore, the base material can further include one or more selected from illite, germanium, mica, maifan stone, jade, amethyst, and charcoal. The base material can be, for example, a mixture of sand and cement, a soil (loess, clay, kaolin, and / or dredged soil), and sludge, and can further include, as an additional component, one or more selected from illite, germanium, mica, maifan stone, jade, amethyst, and charcoal.

[0033] The dredged soil is deposited on or around the bottom of rivers, streams, reservoirs, and coastal areas, and can be collected, dried, and pulverized for use. The sludge can be selected from sludge from water treatment plants, sludge from sewage / wastewater treatment plants, paper sludge, and / or sludge from sewage treatment plants. For example, inorganic sludge having an inorganic content of 40 wt% or more of the solid content can be used. For example, sludge from a water purification plant can be dehydrated, dried, and pulverized.

[0034] According to an embodiment of the present invention, the brick material may include one or more base materials selected from particles such as soil (such as loess, clay, kaolin, and / or dredged soil) and sludge, and a solidifying agent for solidifying the base material. In this case, the base material may be, for example, a material having an average particle size (D) of 20 to 1,000 mesh. 50 ), and in certain instances, can have an average particle size (D 50 Such a base material may comprise, for example, 70 to 98 wt %, 75 to 96 wt %, or 80 to 95 wt % based on the total weight (based on the solid content) of the brick material.

[0035] The solidifying agent functions to bind the particles of the base material together. The particles of the base material are firmly bound by the solidifying agent, resulting in a solidified brick with at least improved strength. The solidifying agent can be contained in an amount of, for example, 0.1 to 12 wt %, 0.2 to 10 wt %, or 0.5 to 8 wt % of the total weight (based on the solid content) of the brick material.

[0036] According to an embodiment of the present invention, the solidifying agent includes sodium silicate (Na2SiO3), sodium chloride (NaCl), potassium chloride (KCl), calcium chloride (CaCl2), sodium sulfate (Na2SO4), and citric acid. According to a preferred embodiment of the present invention, the solidifying agent preferably includes 100 parts by weight of sodium silicate (Na2SiO3), 10-30 parts by weight of sodium chloride (NaCl), 15-40 parts by weight of potassium chloride (KCl), 10-30 parts by weight of calcium chloride (CaCl2), 2-8 parts by weight of sodium sulfate (Na2SO4), and 1-6 parts by weight of citric acid. A solidifying agent with these components and amounts firmly binds (solidifies) particles of base materials such as loess, preventing staining of the loess when in contact with the human body, and effectively improves the surface hardness and strength (compressive strength, tensile strength, fracture strength, bending strength, etc.) of the brick. Bricks according to the present invention, containing the above-described solidifying agent, may have a compressive strength of, for example, 32 MPa or more or 35 MPa or more.

[0037] Furthermore, according to another embodiment of the present invention, the solidifying agent contains the above-mentioned sodium silicate (Na2SiO3), sodium chloride (NaCl), potassium chloride (KCl), calcium chloride (CaCl2), sodium sulfate (Na2SO4), and citric acid as active ingredients, but may also contain additional additives.

[0038] The additives are not particularly limited. For example, they can be selected from trace amounts of cobalt (Co) compounds, phosphorus (P) compounds, barium (Ba) compounds, magnesium (Mg) compounds, aluminum (Al) compounds, silicon (Si) compounds, fluorine (F) compounds, iron (Fe) compounds, lignin sulfonates, and / or basic compounds (such as NaOH). These additives can be included in an amount of, for example, 0.005 to 2 parts by weight each, per 100 parts by weight of the sodium silicate (Na2SiO3).

[0039] According to another embodiment of the present invention, the brick material includes the above-described base material and hardener as active ingredients, and may further include a reinforcing material for strength enhancement. The reinforcing material may be selected from fiber and / or cement. The fiber may be ground material such as pulp, fabric, and / or nonwoven fabric. Furthermore, the brick material may further include an appropriate amount of water for the fabric and / or a coloring material (pigment) for color realization, if necessary.

[0040] According to a specific embodiment of the present invention, the brick material may include one or more base materials selected from particles such as soil (such as loess, clay, kaolin, and / or dredged soil) and sludge, a hardening agent for hardening the base material, and cement for strengthening the bonding strength. In this case, the brick material may include, for example, 75 to 96 wt% of the base material, 0.2 to 10 wt% of the hardening agent, and 2 to 15 wt% of the cement.

[0041] Referring to FIG. 1, the brick manufacturing apparatus according to the present invention may include a material sorter 10 for sorting brick materials to ensure uniformity of the brick material and / or a crusher (not shown) for crushing the brick materials. The material sorter 10 and crusher may be installed at the end of an extruder 100. The material sorter 10 screens (sieves) and removes stones and other impurities from soil, such as loess or dredged soil. The material sorter may include a screen net capable of screening uniformly sized materials. When soil, such as loess, clay, and / or dredged soil, is used as the base material for bricks, the material sorter 10 is used to remove stones and other impurities from the soil, and the soil is crushed using a crusher such as a roll crusher, and then sieved to obtain uniform, fine particles.

[0042] The brick material is supplied to the extruder 100. The brick material has a base material and a solidified body as active ingredients, and is mixed with an appropriate amount of water to have a viscosity that can be extruded by the extruder 100. The brick material can be mixed to have an appropriate viscosity in the extruder 100, but in another embodiment of the present invention, the brick material can be mixed in a separate mixer 20 for uniform mixing and then supplied to the extruder 100. For this purpose, the brick manufacturing apparatus according to the present invention can further include a mixer 20 provided at the tip of the extruder 100.

[0043] The mixer 20 mixes the brick material with water to create a viscous dough. For example, the mixer 20 may be a mixing device selected from a stirrer and a water mixer. Referring to FIG. 1, the mixer 20 kneads the brick material while moving it forward. The mixer 20 may be a water mixer having one or more kneaders 22 inside a housing 21. The kneader 22 includes a rotating shaft 22a and a plurality of kneader blades 22b formed around the rotating shaft 22a. When the brick material is inserted into the inlet 21a of the housing 21, the rotation of the rotating shaft 22a rotates the kneader blades 22b. The brick material is kneaded by the rotation of the kneader blades 22b and discharged through the outlet 21b. Here, a base material (e.g., soil particles such as loess, clay, kaolin, and / or dredged soil) and a solidifying agent solution may be separately injected into the inlet 21a of the housing 21. The solidifying agent solution is a solution in which a solidifying agent is dissolved in water, and it is useful to mix a solidifying agent having the above-mentioned components and content in water.

[0044] The extruder 100 extrudes brick material toward the mold 200, and may be a commonly used extruder (or extrusion molding machine). The extruder 100 includes an extruder body 120 forming an internal space, a feed screw 140 installed inside the extruder body 120, and an extrusion section 160 formed on one side (the right side of the drawing) of the extruder body 120. A hopper 110 into which brick material is introduced may be attached to the other side (the left side of the drawing) of the extruder body 120. One or more feed screws 140 may be attached inside the extruder body 120. A twin-screw extruder 100 equipped with two feed screws 140 is shown in the drawing (see FIG. 3).

[0045] According to an embodiment of the present invention, the extrusion unit 160 is integrally formed on one side of the extruder body 120, and due to the denseness of the brick structure, it may have a smaller inner diameter (specification) than the extruder body 120. That is, the extrusion unit 160 may be formed on one side of the extruder body 120, with a cross section (inner diameter) that is reduced in the extrusion direction (right side of the drawing).

[0046] In the present invention, the term "cross section" refers to a cross section perpendicular (orthogonal) to the extrusion direction (the direction of the arrow in the drawing). Also, in the present invention, the terms "inner diameter" and "specification" refer to one or more lengths (dimensions) selected from the horizontal length and vertical length in the cross section of a component (cross section perpendicular to the extrusion direction).

[0047] The brick material flowing into the extruder body 120 through the hopper 110 is extruded (discharged) from the extrusion section 160 toward the mold 200 by the extrusion force generated by the rotation of the feed screw 140. In this case, the extrudate (P) has a dense structure (increased density of the brick material) as it passes through the extrusion section 160, which has a smaller inner diameter (cross section) than the extruder body 120. The extrudate (P) extruded from the extrusion section 160 is supplied to the inside of the mold 200.

[0048] The mold 200 receives the extrudate (P) extruded from the extrusion unit 160, forms it into a molded body (F) of a predetermined shape, and discharges it. The extrudate (P) extruded from the extrusion unit 160 and the molded body (F) formed by the mold 200 may have the same cross-section (size), but depending on the embodiment of the present invention, the molded body (F) formed by the mold 200 may have a larger cross-section (size) than the extrudate (P) extruded from the extrusion unit 160. In this case, the mold 200 may be provided as an expansion mold depending on the embodiment of the present invention. Therefore, the mold 200 forms a molded body (F) having a larger cross-section (size) than the extrudate (P) extruded from the extrusion unit 160.

[0049] The extension mold 200 includes an expansion section 210 (see FIG. 3), whose inner diameter cross section gradually expands in the extrusion direction (to the right of the drawing), and an expansion molding section 220 formed on one side (to the right of the drawing) of the expansion section 210. The expansion section 210 is connected to the extrusion section 160 and receives the extrusion (P) extruded from the extrusion section 160. The expansion molding section 220 forms a molding (F) having a larger inner diameter (horizontal area) than the extrusion section 160 over the total length (L) (see FIG. 4) and a larger cross section (specification) than the extrusion (P). The expansion molding section 220 may have a cross-sectional shape, such as a rectangle or square. The expansion section 210 may also be formed with an air outlet (not shown) through which air can be discharged. Multiple air outlets may be formed in the expansion section 210, which allow air to be discharged when the extrusion (P) is introduced, improving the density of the brick structure (minimizing porosity).

[0050] The expansion mold 200 may have an integral structure fixedly connected to the extrusion unit 160. According to another embodiment of the present invention, the expansion mold 200 may be detachably connected (connected and separated) to the extrusion unit 160. The expansion mold 200 may be detachably connected to the extrusion unit 160 via a joint member such as a flange. In this case, the expansion mold 200 may be replaced with one having a different inner diameter (cross-section) as needed (i.e., the inner diameter (cross-section) of the expansion molding unit 220 may be replaced with another one), thereby variably manufacturing bricks of various sizes (cross-sections).

[0051] According to another embodiment of the present invention, the expansion mold 200 may include a guide part 230 formed on one side (right side in the drawing) of the expansion molding part 220. The guide part 230 is integrally formed as an extension on one side (right side in the drawing) of the expansion molding part 220 and may have an open top structure. According to a specific embodiment, the expansion mold 200 has a cross-sectional shape that is closed on top, bottom, left and right in the case of the expansion part 210 and the expansion molding part 220, and has an approximately square-shaped cross section in the case of the guide part 230. In this case, the guide portion 23 may have an open top structure and a roughly "U" shaped cross section. 0 provides an installation space for the loading means 300 at the start of brick production (when the initial extrudate (P) is introduced), and after the loading means 300 is removed, it guides the molded body (F) discharged from the expansion molding section 220.

[0052] The loading means 300 applies a load to the extrudate (P) supplied from the extrusion section 160 to the mold 200 to control the density (g / cm 3 ) of the extrudate (P). 3 , weight per unit volume), thereby achieving high density. Specifically, the loading means 300 causes the brick material particles (e.g., base material particles such as loess, clay, kaolin, and / or dredged material) constituting the extrudate (P) to pack densely within the mold 200, increasing the density of the extrudate (P), thereby making the brick structure denser and providing at least high strength (high density). Furthermore, when a green body (F) having an expanded cross section (size) compared to the extrudate (P) is formed through the expansion mold 200, the loading means 300 fills (full-fills) the expansion mold 200 with the extrudate (P), thereby enabling the formation of the expanded green body (F) and improving its density.

[0053] According to an embodiment of the present invention, the loading means 300 includes a baffle plate 310 to which the extrudate (P) is closely attached, and a loading member 320 that supports the baffle plate 310 and applies a load.

[0054] The baffle plate 310 is attached inside the mold 200. Specifically, the baffle plate 310 is installed inside the expansion molding section 220 and moves left and right along the length section (L) of the expansion molding section 220 (see FIG. 4). The baffle plate 310 makes it difficult for the extrudate (P) to pass through the expansion molding section 220, thereby increasing the density of the extrudate (P). Specifically, the baffle plate 310 interferes with the forward force (extrusion force) that allows the extrudate (P) that has passed through the expansion section 210 to easily pass through the expansion molding section 220, thereby filling the interior of the expansion section 210 and the expansion molding section 220 with the extrudate (P) and increasing the texture density of the extrudate (P).

[0055] The load member 320 is installed on one side (the right side in the drawing) of the baffle plate 310 to support the baffle plate 310 and simultaneously apply a load to the baffle plate 310. The load member 320 preferably applies a load (resistance) that prevents the baffle plate 310 from being easily pushed by the forward force (extrusion force) of the extrudate (P). More specifically, the load member 320 is selected to have a load force that is smaller than the forward force (extrusion force) of the extrudate (P) and allows the extrudate (P) to slowly pass through the expansion molding portion 220 while remaining in close contact with the baffle plate 310. The load member 320 may be, for example, an elastic member that applies a load while elastically supporting the baffle plate 310. Alternatively, the load member 320 may be, for example, an actuator that applies a load to the baffle plate 310 via an energy source such as electricity, hydraulics, and / or compressed air. According to an embodiment of the present invention, the load member 320 may be an actuator such as a hydraulic cylinder or a pneumatic cylinder. Furthermore, one or more load members 320 may be attached to one side of the baffle plate 310. As shown in the figure, the load member 320 may be an actuator (e.g., a hydraulic cylinder) and may be installed in the inner space of the guide part 230.

[0056] According to another embodiment of the present invention, the loading means 300 may further include a lifting member 340 that moves the loading member 320 up and down. According to yet another embodiment of the present invention, the loading means 300 may further include a rail 350 that allows the lifting member 340 to move left and right. Furthermore, the loading means 300 may further include a support member 360 that can support the rail 350 and / or the lifting member 340.

[0057] The lifting member 340 is installed above the load member 320. In this case, one side (the lower side of the drawing) of the lifting member 340 can be connected to the load member 320, and the other side (the upper side of the drawing) can be connected to the rail 350. Such a lifting member 340 is preferably one that can move the load member 320 up and down, and can be selected from actuators such as a hydraulic cylinder or a pneumatic cylinder. Furthermore, the rail 350 is installed above the lifting member 340. In this case, the rail 350 preferably has a structure that can move the lifting member 340 left and right. As a result, the lifting member 340 moves left and right along the rail 350.

[0058] Therefore, the loading means 300 can move up, down, left, and right by the lifting member 340 and the rail 350. That is, the baffle plate 310 and the loading member 320 can move up, down, left, and right by the lifting member 340 and the rail 350. The baffle plate 310 and the loading member 320 can be removed from the mold 200 by moving up, down, left, and right in this manner. Figure 5 shows the state in which the baffle plate 310 and the loading member 320 are placed on top of the mold 200 after being removed from the mold 200.

[0059] The process for manufacturing bricks using the above-described brick manufacturing apparatus is as follows.

[0060] 1 to 3, brick material is fed into the extruder 100 and extruded. As described above, the brick material can be thoroughly kneaded in the water mixer 20 and then injected into the extruder 100. The extrusion section 160 generates extrudate (P) through extrusion and extrudes (discharges) it in the extrusion direction (the direction of the arrow in the drawings). The extrudate (P) is then supplied to the expansion section 210 of the expansion mold 200. As shown in FIGS. 1 to 3, a loading means 300 is provided in the expansion mold 200. That is, a baffle plate 310 is provided within one side of the expansion molding section 220. More specifically, the baffle plate 310 is inserted into the expansion molding section 220, but is located at the boundary between the expansion section 210 and the expansion molding section 220. The loading member 320 is also provided within the guide section 230.

[0061] 4, when extrudate (P) is continuously fed into the expansion mold 200, the extrudate (P) fills the expansion section 210, and the baffle plate 310 slowly moves due to the forward force (extrusion force) of the extrudate (P). The baffle plate 310 moves in the extrusion direction (to the right in the drawing) along the length section (L) of the expansion molding section 220 and is positioned at the end of the expansion molding section 220, i.e., at the boundary between the expansion molding section 220 and the guide section 230. At this time, as shown in FIG. 4, the extrudate (P) that has passed through the expansion molding section 210 fills the interior of the expansion molding section 220 with a dense structure, forming a compact (F).

[0062] 5, when the baffle plate 310 is positioned at the end of the expansion molding unit 220, the loading means 300 is removed from the molding line (extrusion direction). That is, the baffle plate 310 and the loading member 320 are removed from the expansion mold 200. At this time, as described above, the baffle plate 310 and the loading member 320 are moved upward by the lifting member 340 and the rail 350, and then moved leftward to be removed from the expansion mold 200. As shown in FIG. 5, the baffle plate 310 and the loading member 320 can be positioned above the expansion mold 200 after being removed from the molding line (extrusion direction) of the expansion mold 200. Even after the loading means 300 is removed from the molding line (extrusion direction), the extrudate (P) continues to flow into the expansion molding unit 220, and the molded product (F) is continuously produced by being pushed in the extrusion direction (molding line). The formed body (F) passes through the expansion forming section 220 and is discharged forward along the guide part 230, and then is supplied to the cutter 400 on the feed conveyor 30.

[0063] After the loading means 300 is removed, the extrudate (P) continues to flow into the expansion molding section 220. At this time, the flowing extrudate (P) has a high density due to friction with the inner wall of the expansion molding section 220. That is, after the loading means 300 is removed, the frictional force of contact with the inner wall of the expansion molding section 220 acts as a load, and the extrudate (P) / formed body (F) that continues to flow in even after the loading means 300 is removed has a high density due to the wall friction (load). Considering the degree of density due to the wall friction, the length (L) of the expansion molding section 220 (see FIG. 4) may be 30 cm or more. The length (L) of the expansion molding section 220 may be, for example, 30 cm to 2 m, or 40 cm to 1.5 m.

[0064] According to another embodiment of the present invention, the loading means 300 may further include a sensor (not shown) for detecting the position of the baffle plate 310, and a control unit (not shown) for controlling at least the lifting member 340 in accordance with a detection signal from the sensor. In this case, the sensor may be installed at an end of the expansion molding section 220 or at the boundary between the expansion molding section 220 and the guide section 230, and may send a signal to the control unit when the baffle plate 310 reaches the boundary. Furthermore, the control unit may operate the lifting member 340 to control the baffle plate 310 and the loading member 320 to be removed from the molding line (extrusion direction).

[0065] The cutter 400 is provided at the rear end of the expansion mold 200, i.e., in the extrusion direction (right side in the drawing), and cuts the molded body discharged from the mold 200 to a predetermined length. A commonly used cutter can be used as the cutter 400. The cutter 400 may include a blade, a sawtooth, a wire-shaped notch, or the like.

[0066] A feed conveyor 30 may be provided on the bottom of the cutter 400. The green bodies cut to a certain length by the cutter 400 are continuously transported via the feed conveyor 30. The green bodies transported via the feed conveyor 30 are then dried to complete the brick production. The green bodies may be dried after being stacked in multiple layers on a tray. Furthermore, the green bodies may be naturally dried and / or hot-air dried, and in some cases, may be fired at high temperatures in a firing furnace.

[0067] After a certain amount of bricks is produced by the above-mentioned extrusion, molding, cutting, and drying, the loading means 300 is returned to its original position and the manufacturing process is repeated. For example, after the brick production or brick material consumption for one day is completed, the baffle plate 320 and the loading member 320 of the loading means 310 are placed on the molding line (extrusion line) and the manufacturing process is repeated.

[0068] According to the manufacturing apparatus of the present invention described above, bricks can be manufactured by a continuous extrusion process, and at the same time, high-strength (high-density) bricks having a high-density structure can be manufactured through the loading means 300. Furthermore, according to the present invention, bricks having a high-density structure and a larger cross section (size) than the extrusion portion 160 can be manufactured through the loading means 300 and the expansion mold 200.

[0069] Referring to Figure 6, the present invention is characterized in that the loading means 300 applies a load to the extrudate (P) to increase the density of the particle structure, and also fills the expansion section 210 and the expansion molding section 220 with the extrudate (P), thereby producing an expanded molded product (F) having a larger cross-section (size) than the extrusion section 160. Figure 7 is a comparative example to Figure 6 of the present invention. As shown in Figure 7, if the loading means 300 is not provided, the extrudate (P) easily advances in the extrusion direction. In this case, the extrudate (P) does not fill the expansion section 210 and the expansion molding section 220, making it difficult to form the expanded molded product (F) and achieving a high density (particle structure density).

[0070] Meanwhile, the brick manufacturing apparatus according to the present invention may further include a moving means capable of mounting and moving the above-described apparatus components (100, 200, 300, 400) according to other embodiments. The moving means is preferably a means for mounting and moving the apparatus components (100, 200, 300, 400). The moving means may be a transportation means such as a vehicle, for example, a trailer. Generally, large trailers are equipped with a hydraulic power pack, through which the necessary hydraulic pressure can be supplied from the actuators (hydraulic cylinders) constituting the load member 320 and the lifting member 340 of the load means 300.

[0071] The transport means (such as a trailer) may be equipped with the extruder 100, expansion mold 200, loading means 300 and cutter 400 described above, and may also be equipped with a material sorter 10, mixer 20, grinder and / or feed conveyor 30 in some cases.

[0072] When the brick manufacturing apparatus according to the present invention further includes the above-mentioned transportation means, it can be transported to, for example, a building construction site (a construction site for the walls of a building) and directly manufacture and supply bricks at the construction site. Furthermore, the brick manufacturing apparatus according to the present invention can be transported to a brick material collection site and manufacture bricks not only at a building construction site but also at a brick material collection site. Specifically, it can be transported by a transportation means to a brick material collection site (e.g., a site where a large amount of soil such as loess, clay, kaolin, and / or dredged soil is distributed) and manufacture bricks using the soil at the collection site. In this case, it is possible to reduce at least the transportation and storage costs of the brick material, thereby lowering the unit price of brick supply.

[0073] Examples and comparative examples of the present invention are provided below. The following examples and comparative examples illustrate brick manufacturing examples. Specifically, experimental examples are provided according to the composition and content of the solidifying agent. The following examples are provided as examples to aid in understanding the present invention and are not intended to limit the technical scope of the present invention. Furthermore, the following comparative examples are not intended to represent prior art and are provided solely for comparison with the examples.

[0074] [Example 1] A mixed powder material was prepared by mixing loess powder with an average particle size of approximately 350 mesh, which has excellent drying properties, and commercially available Portland cement. A solidifying agent solution, a mixture of water and a solidifying agent, was also prepared. The mixed powder material and the solidifying agent solution were then placed in a mold to produce a brick body measuring approximately 60 mm x 60 mm x 180 mm. The mixture contained approximately 88% by weight of loess powder, approximately 9.6% by weight of cement, and approximately 2.4% by weight of solidifying agent, based on the solid content. The solidifying agent contained approximately 14 parts by weight of sodium chloride (NaCl), approximately 26 parts by weight of potassium chloride (KCl), approximately 16 parts by weight of calcium chloride (CaCl), approximately 4 parts by weight of sodium sulfate (NaSO), and approximately 3 parts by weight of citric acid, relative to 100 parts by weight of sodium silicate (NaSiO).

[0075] The molded bricks were cured at room temperature for three days, after which the compressive strength and the degree of staining were evaluated, and the results are shown in Table 1 below. The compressive strength of the brick test pieces (after three days of curing) was measured in a conventional manner using a compressive strength tester. The degree of staining was evaluated by rubbing the brick test pieces (after three days of curing) several times, and if yellow soil was found on the finger, it was rated as "present," and if almost no yellow soil was found on the finger, it was rated as "absent," and the results are shown in Table 1.

[0076] [Comparative Examples 1 and 2] Brick specimens according to each Comparative Example were manufactured in the same manner as in Example 1, except that the composition (components and content) of the hardener was different from that of Example 1. The composition (composition and content) of the hardener used in each Comparative Example is shown in Table 1 below. In addition, the compressive strength and degree of staining of the brick specimens according to each Comparative Example (after 3 days of curing) were evaluated in the same manner as in Example 1, and the results are shown in Table 1.

[0077] [Table 1]

[0078] As shown in Table 1, it was found that the properties of the brick specimens differed depending on the components and content of the solidifying agent. According to this experimental example, when the solidifying agent was appropriately formulated with the same components and content as in Example 1, it was found to have higher strength (high compressive strength of approximately 36 MPa or more) than other examples (Comparative Examples 1 and 2), and no loess staining occurred. [Industrial Applicability]

[0079] The bricks according to the present invention have at least improved strength and are useful in industrial fields. Furthermore, the present invention enables the production of high-strength (high-density) bricks by a continuous extrusion process, thereby improving productivity and enabling the production of large-sized bricks using an expansion mold.

Claims

1. An extruder (100) for extruding brick material, comprising an extruder body (120) provided with a feed screw (140), and an extruder (160) formed on one side of the extruder body (120); a mold (200) for receiving the extrudate (P) extruded from the extrusion section (160) and forming it into a molded body (F); a loading means (300) for applying a load to the extrudate (P) supplied from the extrusion section (160) to the mold (200) to increase the density of the extrudate (P); and a cutter (400) for cutting the molded body (F) discharged from the mold (200); The brick material is a base material; and A brick manufacturing apparatus comprising a hardening agent for hardening the base material.

2. The solidifying agent is sodium silicate (Na 2 SiO 3 ), sodium chloride (NaCl), potassium chloride (KCl), calcium chloride (CaCl 2 ), sodium sulfate (Na 2 SO 4 2. The brick manufacturing apparatus according to claim 1, characterized in that the mixture contains citric acid.

3. The brick manufacturing apparatus according to claim 1, characterized in that the mold (200) includes an expansion mold (200) for forming a molded body (F) having a cross section (cross section perpendicular to the extrusion direction) larger than the extrudate (P) extruded from the extrusion section (160).

4. The expansion mold (200) an extension portion (210) attached to said extrusion portion (160); An extended molded portion (220) is molded on one side of the extrusion portion (160) to form a molded body (F) having a cross section (cross section perpendicular to the extrusion direction) larger than that of the extrudate (P); and The guide portion (230) is formed on one side of the expansion molding portion (220), The loading means (300) a baffle plate (310) provided inside the expansion molding portion (220) and in close contact with the extrudate (P); a load member (320) provided inside the guide portion (230) to support and apply a load to the baffle plate (310); A lifting member (340) provided on the upper part of the load member (320) for moving the load member (320) up and down; and 4. The brick manufacturing apparatus according to claim 3, further comprising a rail (350) provided on an upper portion of the lifting member (340) for moving the lifting member (340) left and right.

5. Mixing brick materials; and forming the mixed brick material; The brick material is a base material; and A brick manufacturing method comprising the step of adding a hardening agent to harden the base material.

6. The solidifying agent is sodium silicate (Na 2 SiO 3 ), sodium chloride (NaCl), potassium chloride (KCl), calcium chloride (CaCl 2 ), sodium sulfate (Na 2 SO 4 6. The brick manufacturing method according to claim 5, characterized in that the mixture contains citric acid.

7. 6. A brick manufacturing method according to claim 5, characterized in that the brick manufacturing apparatus according to claim 1 is used.

8. a base material; and A brick comprising a hardening agent that hardens the base material.

9. The solidifying agent is sodium silicate (Na 2 SiO 3 ), sodium chloride (NaCl), potassium chloride (KCl), calcium chloride (CaCl 2 ), sodium sulfate (Na 2 SO 4 9. The brick of claim 8, further comprising citric acid.

10. The bricks are manufactured using the brick manufacturing apparatus according to claim 1, 9. The brick of claim 8, wherein the base material comprises one or more selected from soil and sludge.

11. The brick further includes a reinforcing material for strength reinforcement and has a compressive strength of 32 MPa or more; the base material comprises one or more selected from the group consisting of loess, clay, kaolin, dredged soil, and sludge; 10. The brick according to claim 9, wherein the reinforcing material comprises one or more selected from the group consisting of a fiber material and cement.

12. The solidifying agent is sodium silicate (Na 2 SiO 3 100 parts by weight of sodium chloride (NaCl), 10 to 30 parts by weight of potassium chloride (KCl), 15 to 40 parts by weight of calcium chloride (CaCl 2 ) 10 to 30 parts by weight, sodium sulfate (Na 2 SO 4 10. The brick according to claim 9, characterized in that it contains 2 to 8 parts by weight of sucrose and 1 to 6 parts by weight of citric acid.

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