Low temperature method of production for construction ceramics with varied textures

Abstract

The present invention focuses on the production process of low temperature construction ceramic parts with new textures. These parts are processed at temperatures lower than traditional ceramics, offering unique designs and characteristics without the need for firing. The process involves using stone waste and includes mixing raw materials, molding, processing at low temperatures, sanding, texturing, and applying coatings if necessary. The resulting ceramic parts have high color stability, mechanical resistance, and adhesion to cement mortar. Additionally, they have reduced energy consumption and CO2 gas production compared to traditional fired ceramics. Different types of concrete compounds are utilized for production, including self-compacting, geopolymeric, and fiber-containing compounds.

Description

Low Temperature Method of Production for Construction Ceramics with Varied Textures

[0001] The present invention involves the production process of construction ceramic parts at low temperature with innovative textures and designs. These parts are created using a cutting-edge method that involves processing them at temperatures lower than traditional ceramics, eliminating the need for firing.

[0002] After the initial processing, the parts undergo sanding, texturing, and in some cases, the application of coatings to enhance their appearance and performance. The final products feature high color stability, mechanical resistance, and exceptional adhesion to cement mortar, making them ideal for a wide range of construction applications.

[0003] To further enhance the versatility of these ceramic parts, various types of concrete compounds are utilized in the production process, including self-compacting, geopolymeric, and fiber-containing compounds. This allows for a wide range of textures, colors, and finishes to be achieved, catering to diverse design preferences and project requirements.

[0004] C04B 35 / 00

[0005] CN201483841U

[0006] Concrete Non-Stick Sanitary Ware

[0007] The utility model provides a concrete non-stick sanitary ware, comprising a sanitary ware body made of concrete, a non-stick layer being arranged on the inner surface of the sanitary ware body; a steel bar can also be arranged inside the sanitary ware body to strengthen the internal tension of the sanitary ware. The utility model is realized, not only the raw materials are abundant and easy to obtain, but also the stains are difficult to adhere to the sanitary ware, easy to clean, and at the same time plays the role of water saving.

[0008] The mentioned invention shares certain qualities with our claimed one, as they both feature anti-pollution surface coatings. However, our solution, unlike this one, can be applied to not only sanitary ware but also other ceramic pieces and it provides a whole array of textures and colors in terms of final product design.

[0009] CN115072773

[0010] TEMPLATE FOR TEXTURED LEAD ZIRCONATE TITANATE-BASED CERAMIC AND PREPARATION METHOD THEREOF

[0011] The invention provides a template for textured lead zirconate titanate-based ceramic and a preparation method thereof, the method specifically comprises the following steps: taking flaky Na2Ti3-yByO7 (0.03 < y < 3), B is a surface Zr element or an Hf element, mixing the flaky Na2Ti3-yByO7 with a set amount of a barium source, a strontium source or a lead source to obtain a mixture, the molar ratio of Na2Ti (3-y) ByO7 in the mixture C to the barium source, the strontium source or the lead source is 1: (1-14), 1: (1-17.5) and 1: (1-20) respectively; the mass of the sodium salt is 1-4 times that of the mixture C, the mixture C is subjected to heat preservation for 0.5-10 h in the high-temperature environment of 850-1100 DEG C, a molten salt product is obtained, water-soluble salt of the molten salt product is cleaned with deionized water and inorganic acid with the set concentration in sequence, the high-yield and high-quality ABxTi1-xO3 template is finally obtained, A is Ba, Sr and Pb, x is larger than 0.01 and smaller than 1, and x is larger than 0.01 and smaller than 1. Compared with a method used in the prior art, the method has the advantages that the production cost is low, the environmental pollution is less, the bismuth element does not participate in the template manufacturing process, the repeated pickling step does not exist, and the template yield is relatively higher.

[0012] This mentioned invention and our claimed design both offer environmentally friendly solutions in the field of ceramic making and they both emphasize unique textures in the final products. But their methods and material as well as the process of achieving the texture is completely different.

[0013] CN108129131

[0014] LOW-TEMPERATURE PREPARATION METHOD FOR LIGHTWEIGHT HEAT-INSULATION CERAMICS

[0015] The invention discloses a low-temperature preparation method for lightweight heat-insulation ceramics. Raw materials used in the preparation method comprise construction waste, ceramic polishing slag,fly ash, talc, feldspar, ball clay, diatomite and a foaming agent, wherein the amount of the solid waste is 60% or more. Pre-treated construction waste and other raw materials are subjected to ball milling mixing, and then subject to granulation, compaction molding, drying and low temperature sintering (700-1200 DEG C) to prepare the environmentally friendly lightweight heat-insulation ceramics.The method is simple in process, low in production cost and suitable for industrialized production. The prepared lightweight heat-insulation ceramics have the advantages of low density, controllable pore size, low heat conductivity, excellent mechanical properties and the like, and can be widely applied in heat preservation and heat insulation in the fields of architecture, chemical industry and the like. While achieving low temperature sintering, energy saving and emission reduction, the method can promote high-efficiency resource utilization of the solid waste, and is of great significance to the ecological environment.

[0016] This invention and our claimed one both use a low-temperature method of manufacturing their products, however, this one emphasizes heat insulation application while ours focuses primarily on texture formation and variety of designs.

[0017] JP1999171635

[0018] PRODUCTION OF CERAMIC FOR CONSTRUCTION

[0019] To provide a method for producing ceramic for construction, capable of applying unused resource and contributing to saving of resource and energy by sintering a base material composition obtained by compounding refractory granules as a main raw material with a silicic acid alkali-based component, low melting point metal-based component and one or more kinds of materials selected from an alkaline earth metal salt, an aluminum salt and a polyacrylic acid-based polymer at a low temperature.

[0020] This mentioned patent and ours share some common ground in their choice of raw material and energy optimization when It comes to their method of production, however, this one does not have a primary focus on designing various textures and colors like ours does.

[0021] CN106365673

[0022] LOW-TEMPERATURE QUICK BURNING DAILY CERAMIC AND PRODUCTION PROCESS THEREOF

[0023] The invention relates to the technical field of ceramic production, in particular to low-temperature quick burning daily ceramic and a production process thereof. According to the low-temperature quick burning daily ceramic and the production process thereof, main raw materials suitable for low-temperature quick burning are selected, and most of the raw materials are selected from materials which are abundant in resources, low in cost and highly available; the raw material resources can be fully used, and the production cost is reduced; by control over the particle size distribution, the raw material constituents and burning of the raw materials, substantial reduction of the burning temperature is realized. Air bubbles exist in the ceramic burnt by a burning method of the low-temperature quick burning daily ceramic due to a microstructure, so that the ceramic is light in mass, and all performance indexes can meet the requirement on a daily ceramic blank body; the low-temperature quick burning daily ceramic and the production process thereof have important significance for development of cyclic economy and construction of a resource-saving and environment-friendly society.

[0024] The above mentioned patent is similar to ours in highlighting the low-temperature preparation method and cost-effective solution but their execution and purpose vary. While this one emphasizes quick burning and use of air bubbles, ours focuses on creating a variety of textures and bubbles as well as surface protecting agents.

[0025] The subject of the present invention is the production process of low temperature construction ceramic parts with new and diverse textures. Ceramic parts are divided into two general categories: ceramics fired at high temperature (900 to 1500 degrees) and ceramics processed at low temperature. Although the second category is processed at a low temperature, they do not have the appearance of the first category ceramics.

[0026] The present invention includes the introduction of a new process for the production of building ceramic parts, without the need for firing, and using stone waste, which features such as the possibility of creating beautiful textures and designs on the product, color variety, high color stability, It has high mechanical resistance, reduced energy consumption and CO2 gas production compared to fired ceramic products, high adhesion to cement mortar, lack of scale and discoloration on the surface.

[0027] The production process of construction parts in the present invention includes the mixing of raw materials and mortar preparation, molding, processing at 20 to 120 degrees, sanding, texturing and applying surface coatings if needed. In the present invention, 3 types of concrete compounds including self-compacting, geopolymeric and fiber-containing compounds are used for the production of construction parts.

[0028] Ceramic pieces, in technical terms, have different types. Some of them are ceramics that are baked at high temperature, among these pieces we can mention porcelain and brickwork. Another category of ceramics, such as cement and geopolymer compounds, do not require high temperature for processing.

[0029] The first category of ceramics is usually baked at high temperature (900 to 1500 degrees Celsius) and valuable and high-quality soils are used for their production. As a result, the production of these products causes high consumption of fossil fuels, environmental pollution and loss of soil and valuable mineral resources. On the other hand, baking these products creates a beautiful appearance on their surface and they are usually used in buildings.

[0030] Although the second category of ceramics is processed at a low temperature and does not have the problems caused by firing at a high temperature, they do not have the visual appeal of the first category ceramics.

[0031] Clay brick cladding has been used in building construction for many years and has made many improvements over the years. Now these bricks are available in the market in different sizes, shapes and designs. The water in these bricks evaporates during the baking process and creates many pores in it, and as a result, it absorbs water on top of the brick. The absorption of water on top of clay bricks makes them stick well to the mortar, but at the same time, it also creates problems, such as the possibility of scale formation due to the migration of scale-causing agents and salts to the surface of the brick, the possibility of cracks caused by the freezing process in the cold season, and the possibility of the surface of the brick being dirty and stained due to pouring cement mortar on the brick during facade painting.

[0032] The present invention includes the introduction of a new process for the production of construction ceramic piecess, without the need for firing and using stone waste, which features the possibility of creating beautiful and unique textures and designs on the surface of the product. It also achieves qualities such as color variety, high color stability, compressive strength of 30 to 90 MPa and bending strength of 4 to 30 MPa (depending on the type of composition and molding method), 60 to 80 percent reduction in production energy consumption and 40 percent reduction in greenhouse gas (CO2) production compared to ceramics made with firing, no scale and discoloration on the surface, high adhesion to mortar for brick products (shear strength of the surface attached to the mortar above 420 kilopascals) and resistance to atmospheric conditions.

[0033] In addition to the stated features, in the present invention, natural stone waste is used in the production of parts without firing, which solves the problem of accumulating and disposing of stone waste in nature and using valuable soil to produce ceramic parts with firing.Solution of Problem

[0034] The present invention includes the introduction of a new process for the production of construction ceramic parts, without the need for firing, and using stone waste, which features qualities such as the possibility of creating beautiful textures and designs on the product, color variety, high color stability, high mechanical resistance, reduction of energy consumption and CO2 gas production compared to ceramic products with firing, high adhesion of brick products to cement mortar, lack of dandruff and discoloration on the surface.

[0035] The production process of building parts without baking in the present invention includes the steps of mixing raw materials and preparing mortar, molding, processing at 20 to 120 degrees Celsius, sanding, texturing and applying surface coatings if needed. It should be noted that in the current process, the order of the sanding stage and texturing can be changed (Figure No. 8).

[0036] In the present invention, by introducing a new texturing process, it is possible to create beautiful and unique textures on the surface of the product. Also, during the texturing process, the dandruff factors are removed from the surface of the product and by creating surface porosity on the surface of the product, the adhesion of the applied surface coatings increases.

[0037] In the present invention, 3 different types of concrete compounds including self-compacting, geopolymeric and fibrous compounds are used for the production of construction parts.

[0038] In order to increase the adhesion of the unbaked brick product, two methods are introduced in the present invention: creating roughness and porosity, and creating a spongy layer behind the brick. In the following, the details of these methods will be discussed in the molding and sanding stages.

[0039] 1- Mixing raw materials and preparing mortar

[0040] At this stage, the raw materials for the composition of self-compacting concrete or geopolymer are poured into the mixer and mixed for 5 to 10 minutes. In the next step, depending on the type of composition, a solution containing water and superplasticizer (self-compacting compound) or activator (geopolymer compound) is added to the raw materials and mixed to prepare the mortar.

[0041] To prepare fiber concrete, first the raw materials are poured into the mixer at high speed and mixed for 2 to 5 minutes. Then the required water is added to the mixture to make the mixture runny. In the next step, special fibers are gradually added to the mortar. In the last step, superplasticizer is added so that the mortar reaches the desired fluidity.

[0042] 1-1- Self-compacting concrete composition

[0043] The raw materials of the self-compacting composition include cement in the amount of 10-35% and in the best case 20-30%, stone waste in the amount of 45-90% and in the best case 60-80%, lightweight aggregates such as pumice and perlite (depending on the dimensions of the brick and the type of molding process) in the amount of 0 to 20% and in the best case 0 to 12%, silica grains (depending on the type of molding and texturing process) in the amount of 0 to 10%, other fillers It is 0-45% and additives are 0-3% by weight.

[0044] Lightweight aggregate is added to create a spongy layer behind the brick or to lighten the product, which is discussed in detail in the molding and sublimation stages.

[0045] Among the silica grains are the crushed grains of colorless and colored glass with a grain size of 0.15 to 10 mm. Depending on the type of texturing process and the designs they create on the surface of the product after texturing, these grains can be added to the composition of raw materials or in the molding process or be added to the bottom of the mold before pouring the mortar.

[0046] The fillers are materials such as ordinary sand and silica grains, blown sand and crushed construction debris.

[0047] The percentage of adding the said superplasticizer in the composition of self-compacting and fibrous concrete, which can be normal plasticizer or hyperplasticizer, can vary between 0.5 and 2% and in a better case between 0.7 and 1.2% by weight of cement materials.

[0048] 1-2- Fiber-reinforced concrete composition

[0049] The raw materials of fiberous concrete composition include cement in the amount of 15 to 75% and in the better case 35 to 65% and in the best case 40 to 55%, stone waste in the amount of 15 to 80% and in the best case 30 to 60%, lightweight aggregates such as pumice and perlite (depending on the size of the brick and the type of molding process) in the amount of 0 to 20% and in the best case 0 to 12%, silica grains (depending on the type of molding and texturing process) in the amount of 0-10%, filler in the amount of 0-45% and additives in the amount of 0-3% by weight.

[0050] The percentage of adding fibers is 1 to 7 percent and in the best case 2.5 to 5.6 percent by weight of raw materials.

[0051] In the present invention, in cases where bending strength is important at the same time as lightness (the thin thickness of the product) is important (such as the construction of cabinets, sinks, basins and unfired brick cladding with large dimensions), fiber concrete composition is used. The bending strength of this composition can increase up to 30 MPa depending on the process and the amount of cement and fibers used.

[0052] 1-3- - Geopolymer concrete composition

[0053] The raw materials of the geopolymer compound are the same as the self-compacting compound, with the difference that a binder is used instead of cement. This binder can be materials such as iron smelting furnace slag, kaolin clay, metakaolin and fly ash.

[0054] The special activating agent for geopolymer composition can be materials such as sodium silicate, sodium carbonate, sodium hydroxide, potassium hydroxide and lime. Depending on the type of composition, the percentage of adding activator can vary between 4 and 30%, and in the best case, between 8 and 22% by weight of the binder.

[0055] 2- Molding

[0056] At this stage, self-compacting and geopolymeric mortar is poured into molds with different dimensions and shapes and placed under vibration or press. It should be noted that the pressure molding method has a ratio of water to cement between 5 and 25 percent by weight and is used when pumice or sponge pieces are not used behind the product.

[0057] Molding of fiber concrete mortar is done by vibrating or spraying concrete on the mold (depending on the shape of the mold, the amount of fibers in the composition and the required bending strength). In the case of spray molding, after each layer is sprayed on the mold, the mortar is compressed by a roller.

[0058] As mentioned in the introduction, one of the ways to increase the adhesion in the brick product in the present invention is to create a sponge layer on the back of the product, which is done in two ways:

[0059] 2-1- The use of lightweight aggregate in the composition

[0060] In this method, self-compacting mortar or geopolymer or fibrous mortar with high fluidity containing light aggregates should be placed on the vibrating table for 1 to 3 minutes. Due to their low density, light aggregates move towards the surface of the mold by means of vibration. At the same time, when the mortar is vibrating, the air trapped in the mortar is released. In the sanding stage, when the back of the product is ground, the cross-section of the light grains is visible and a spongy layer is formed.

[0061] 2-2- Application of light aggregates, sponge pieces or concrete foam block mortar on the back of the brick

[0062] In this method, foam blocks or sponge pieces or ready-made foam concrete block mortar are applied on the back of the product during molding. Light aggregate can be perlite, industrial or mineral pumice or a combination of them.

[0063] The sponge pieces are pieces of light block of Hablex or foam concrete, which are cut in different dimensions and to the appropriate thickness depending on the dimensions of the brick product.

[0064] In order for the light grain and sponge pieces to stick better to the molded mortar, they can be applied to the back of the mortar while it is being vibrated. Sponge parts can only be used in the vibrating production method.

[0065] Ready-made foam concrete block mortar should also be applied to the back of the main mortar after the vibration process, because if this is done during vibration, it will cause the pores inside the foam concrete mortar to disappear.

[0066] 3- Processing

[0067] In the product processing stage, the self-compacting mortar should be kept in a humid environment for 16 to 24 hours at a temperature of 20 to 35 degrees Celsius. Geopolymer mortar should be kept for 4 to 8 hours at a temperature of 30 to 120 degrees and in a better case at a temperature of 50 to 85 degrees Celsius.

[0068] Also, for fibrous mortar, processing should be done in an environment with high humidity and for 1 to 7 days (depending on the desired final strength).

[0069] 4- Sanding

[0070] This part of the process is specific to brick products. As mentioned in the introduction, one of the ways to increase adhesion is to create roughness and porosity behind the brick product. At this stage, when the bricks enter the sanding machine and their backs are sanded and scraped, roughness and porosity are created on their backs and the contact surface of the masonry mortar increases with it, which results in an increase in the adhesion of the bricks to the masonry mortar. On the other hand, according to what was stated in the molding stage, if there are spongy materials (such as pumice, sponge pieces and hardened mortar of foam concrete blocks) behind the brick product, a sponge layer is formed behind it which increases water absorption and adhesion.

[0071] As a result of this stage of the production process, the absorption of water behind the brick product reaches the range of 8% to 25% and it absorbs the mortar well during facade painting.

[0072] 5- Texturing

[0073] The texturing process includes applying a texturizing solution to the surface of the product. Among the advantages of this process, we can mention the creation of beautiful and eye-catching textures and designs on the surface of the product while revealing the fine or coarse grain in the composition, removing surface dandruff and increasing the water absorption of the product.

[0074] 5-1- Texture-forming solution

[0075] The texture-forming solution used for this part of the process must have several key characteristics:

[0076] A. It should scrub the surface of the product, which includes micron sized grains and cement grains, so that the graining of the bottom surface (both fine and coarse) is visible and the surface becomes textured.

[0077] B. It should dissolve the surface salts of the product that cause discoloration and dandruff on the surface.

[0078] C. It should not lower the strength of the product and does not destroy the substrates close to the surface.

[0079] The safety and efficiency of the texturizing solution is achieved through reactive components such as surfactant, emission gas reducing component, gel additives and corrosion inhibitors.

[0080] The reactive component can be one or a combination of substances including amidosulfonic acid, alkanesulfonic acids such as methanesulfonic acid, ethanesulfonic acid, aminomethanesulfonic acid, aminoethanesulfonic acid, orthophosphoric acid, citric acid, ethanoic acid, ethanedioic acid, 2 Butanedioic acid, 2-hydroxypropanoic acid, 2-methylpropanoic acid, taxylic acid, succinic acid, 2,3-dihydroxysuccinic acid, diethylenetriaminepentaacetic acid (DTPA), iminodiacetic acid (IDA), triethylenetetraminehexaacetic acid acid (TTHA), hydroxyacetic acid, orthoboric acid, ascorbic acid, methanesulfonic acid, muriatic acid, fluorohydric acid, azotic acid, alkanesulfonic acids and sodium salts of amidosulfonic acid, sodium citrate, sodium salt of orthophosphoric acid, sodium acid pyrophosphate , ammonium pentaborate, diammonium dihydrogen, ethylene diamine tetraacetate (EDTA), etc.

[0081] The percentage of the reactive component addition depends on the type of composition used and the purpose (texturing of the product, removal of surface scale and increasing surface water absorption). The required intensity of texturing can be between 1% and 100% by weight of the solution and in the optimal state is between 5% and 50% of the weight.

[0082] By reducing the surface tension of the solution, surfactants increase the wetting ability and uniform distribution of the solution on the surface. Also, by increasing the contact surface of the solution, the residual products of tissue formation reaction are pulled out from the pores. Some types of surfactants, such as glycol ethers, also have the ability to dissolve a wide range of materials, including fats, and increase the solubility of the solution. In general, for this purpose, glycerin, ethylene glycol, diethylene glycol, triethylene glycol, alkylbenzene sulfonates such as sodium didecylbenzene sulfonate, glycol ethers such as ethylene glycol monoethyl ether, ethylene glycol monobutyl ether, di Propylene glycol methyl ether, propylene glycol n-butyl ether and their compounds, linear alkyl benzene sulfonate, alkaline salt of linear alkyl benzene sulfonate such as its sodium salt, amines, aryl sulfonates, alkyl sulfonates such as alkyl benzene sulfonate , non-ionic surfactants such as non-ionic alcohol ethoxylate compounds such as octyl phenol ethoxylate and alkyl phenol ethoxylate compounds, lauryl alcohol ethoxylate and alkoxylate alcohols such as alcohol ethoxylate. The amount of adding surfactants can be above 0.01% by weight of the solution, and its ideal state is between 0.04% and 0.4% by weight.

[0083] During the texturing process, odors and gases may be released due to the reactions taking place on the surface. To solve this problem, the emission gas reducing component is used in the solution. While maintaining the reactivity of the solution, this component traps the reactive components in its structure and reduces their volatility. For this purpose, depending on the composition of tissue-forming solution, acrylamide, ammonia, carbonyl diamide, alpha acid amide, alkylurea such as methylurea, alkaneamines such as monoethanolamine, diethanolamine and triethanol amine, alkylamines such as diethylamine and tetraethylamine, copolymers of vinyl pyrrolidone, metaacrylamide and polyvinylpyrrolidone, copolymers of acrylamide and ammonia can be used. Depending on the type of composition, the purpose and the intensity required for texturing, the percentage of adding the emission gas reducing component can vary between 0.05% and 50%, and its ideal state is between 0.5% and 20% by weight of the solution.

[0084] Corrosion inhibitors reduce the corrosion rate of the solution compared to the side surfaces and increase the safety of the solution. For this purpose, sodium iodide, sodium metasilicate, potassium metasilicate, calcium metasilicate, phenylacridine, sulfonates and carboxylates can be used. The amount of adding corrosion inhibitor can be between 0.01% and 3% by weight of the composition, and its ideal state is between 0.04% and 1% by weight of the composition.

[0085] Gel additives also reduce the viscosity of the solution, without affecting other properties of the solution, and reduce the amount of penetration of the solution into the product. Also, as a result, the reactivity of the solution is reduced and more control can be found on the process. For this purpose, we can use galactomannans such as Karaya, Xanthan, Tractate, Guar, Kauri, as well as tara gum and modified guar such as hydroxypropyl guar, hydroxyethyl guar, carboxymethyl hydroxyethyl guar and carboxymethyl hydroxypropyl guar. Cocamide used monoethanolamine and diethanolamine, hydroxymethyl cellulose and hydroxyethyl cellulose. The amount of adding gelling substances can be between 0.05% and 2% by weight of the composition, and its ideal state is between 0.1% and 0.7% by weight of the composition.

[0086] 5-2- Description of the texturizing process

[0087] In the texturing process, the texturizing solution is first applied to the brick. These actions can be in the form of spraying the solution on the surface or immersing the product in the texturizing solution.

[0088] After the texturizing solution reacts well with the surface (depending on the method of applying the texturizing solution, the composition and type of solution and the purpose of texturizing, between 15 seconds and 15 minutes), the products of the reaction must be washed from the surface with water. This can be done with a brush and normal water pressure or with a car wash nozzle. Before washing and during the reaction of the texturizing solution, you can brush on the surface to increase the speed of the reaction and the contact surface of the solution with the surface.

[0089] At the beginning of the texturing process, to reduce the penetration of the texturizing solution in the depth of the product, the surface of the product can be moistened.

[0090] 5-3- - Advantages and specifications of the process

[0091] - Since the level of exfoliation and reactivity of the texturing solution with different components of the product composition, i.e. sub-grain and coarse grain and cement materials, is different, a beautiful and eye-catching texture is created on the surface of the product. This is despite the fact that in processes such as sanding and polishing, a layer is uniformly removed from the surface, and the surface is smooth and polished, and virtually no texture is created in it.

[0092] - Due to the reaction of the texturizing agent with factors that cause dandruff on the surface of the product, such as calcium and sulfate compounds, the texturizing process also prevents the appearance of dandruff on the surface.

[0093] - In the texturing process, there is a possibility of making the surface substrate of the product porous through the reaction of the texturizing substance with the substrate. This feature increases water absorption and as a result increases adhesion in brick products. Also, due to the increased absorption of water and texture created by the texturing process, if a surface coating is applied to the product, the durability of these coatings on the surface increases compared to the non-textured surface.

[0094] - The process of texture generation, due to the visibility of the used granulation, provides the possibility of a wide range of different designs and colors by changing the color and amount of pigment, fine and coarse in the composition of the product and create variety on the surface.

[0095] - In the texturing process, unlike other processes such as sanding and polishing, by adjusting the texturing time and the type and composition of the texturizing solution, it is possible to control more easily and accurately the amount of exfoliation. Based on this, it is also possible to exfoliate at a very low level (on the order of microns) and create beautiful and unique textures, which only contain fine grains.

[0096] - The texturizing solution dissolves impurities attached to silica and granite grains and forms shiny and polished spots on the surface. In this regard, to increase the glossiness of the product surface, granite grains, silica and glass grains can be used in the brick composition or on its surface, as mentioned in the raw material mixing stage. In this case, after the texturing process, these grains are visible and give a special beauty and shine to the surface.

[0097] 6- Application of surface coatings

[0098] After the product dries, coating solutions can be applied to the surface. This coating, depending on the expected use of the product, can be a layer of different resins such as epoxy, acrylic, polyester and vinyl ester or surface protection materials such as waterproof, hydrophobic, anti-pollution and dust-proof materials.

[0099] This step of the process is done depending on the type and application of the product. For example, for non-baking sanitary-building products such as wash basins, ordinary toilets, and counters, a surface protective coating against moisture and chemicals such as polyurethane coatings must be applied. But for brick products, depending on the application (for example, on the exterior of the building), surface coatings such as waterproof and hydrophobic coating can be used, in which case it will not be possible to have dandruff on the product.

[0100] The point that should be taken into consideration at this stage is that waterproofing and hydrophobicizing the surface of brick products, unlike fired bricks, does not reduce the absorption of water beneath the brick. The reason for this is that the processes carried out on the product (sanding and texturing) only increase the absorption of surface water which determines the degree of adhesion of the brick product to the mortar. While the water absorption in the depth of the brick is low in baked bricks, the entire volume of the brick is porous, and if one side is made waterproof and hydrophobic, the other side is also waterproof and loses its adhesion to the mortar.Advantage Effects of the Invention

[0101] 1- High adhesion to the mortar (shear strength of the surface attached to the mortar above 420 kilopascals)

[0102] 2- Creating beautiful and unique textures and designs on the surface of the product

[0103] 3- Color and texture variety and innovativeness

[0104] 4- High color stability

[0105] 5- Compressive strength 30 to 90 MPa

[0106] 6- Bending strength of 4 to 15 MPa

[0107] 7- 60 to 80 percent reduction in production energy consumption compared to fired brick facades.

[0108] 8- No dandruff and discoloration on the surface

[0109] 9- Low water absorption of unbaked brick

[0110] 10- Resistance to all kinds of weather conditions

[0111] 11- Use of stone waste, including crushed waste from mines and quarries, and stone mud instead of using valuable soils.

[0112] 12- 40% reduction in greenhouse gas production (CO2) compared to brick factories with firing

[0113] 13- Stain removal possibility due to the surface coating

[0114] 14- Cost-effective and accessible

[0115] Shows a flowchart of the proposed production method.

[0116] Shows a flowchart of the claimed production method wherein the various stages and their connection can be viewed:

[0117] As seen in the flowchart, the production process of the products consists of prepping and mixing the ingredients, molding, processing at a temperature of 20-120 degrees Celsius, sanding and texturing, drying and coating and lastly packaging.

[0118] The sanding stage (if needed) can be skipped or interchanged with the texturing stage and the application of the surface coating of the product is optional.Examples

[0119] The claimed process of production can be used in manufacturing of several construction products including unfired bricks, fiber concrete counter tops, geopolymer concrete bricks, etc. What follows is an example of the applied process:

[0120] Unfired brick with self-compacting concrete

[0121] Mixing proportions: white cement: 25 kg; 0-5 red marble soil: 70 kg; yellow marble aggregate with size 3-5: 5 kg; industrial pumice: 11.25 kg; water: 10 liters; super plasticizer: 175 grams.

[0122] Mixing and preparing the mortar: First, we mix the raw materials for 5 minutes until the mixture is uniform. Then we gradually add the solution containing superplasticizer and water to obtain a mortar with proper fluidity.

[0123] Molding, processing and sanding: as described in the description for cases where pumice is used in the composition.

[0124] Texturizing:

[0125] Texture-forming compound: Amidosulfonic acid sodium salt: 20% by weight; surfactant: 0.01% by weight; water: 79.99% by weight

[0126] In this example, amidosulfonic acid sodium salt is used as a reactant component. In addition to the basic features that were mentioned in the description section for tissue-forming solution, amidosulfonic acid sodium salt has the following features:

[0127] - Amidosulfonic acid sodium salt does not react with iron and aluminum oxides and does not create additional porosity on the surface.

[0128] - In the reaction of this material with the surface of the brick, dangerous salts for human health and the environment are not produced.

[0129] - It does not emit dangerous gases for human health.

[0130] - The high solubility of this substance makes the process of preparing tissue-forming solution quick and easy.

[0131] In the following, the mechanism and reactions carried out during tissue generation process with sodium salt of amidosulfonic acid are given.

[0132] First, the free limes in the brick are dissolved in the solution and react with sulfamide ions. After finishing the free limes, it is the turn of the limes in the C-S-H gel, which are dissolved in the composition. The result of this reaction is the weakening of the cement structure of the brick surface and peeling and texturing of its surface. Also, sodium ion in the composition increases the solubility of calcium ion and facilitates the sulfamide reaction.

[0133] CaO.2SiO2.4H¬2O(s) → Ca(OH)2(aq), Ca(OH)2(s) → Ca(OH)2(aq)

[0134] Ca(OH)2(aq) + Na+(aq) + H2NSO3- (aq) → Ca(H2NSO3-)2(aq) + Na+(aq) + OH-(aq)

[0135] Based on what was said in the reaction mechanism of sodium amidosulfonic acid salt, this compound reacts with lime dissolved in water and peels off the surface by weakening the cement structure.

[0136] Description of the process of histogenesis

[0137] First, we moisten the surface of the brick. Then we apply the texturizing solution as a spray and uniformly on the surface. The solution should react with the surface for 2 to 5 minutes, depending on the purpose of texturization and desired exfoliation depth. After the reaction, the surface of the brick is washed with a high-pressure stream of water.

[0138] If the purpose of texturing in the present example is only to remove the dander factors from the surface of the brick, texturing can be done in a short time.

[0139] In this example, after completing the texturing process, a beautiful design and a red textured background with yellow grains is created on the surface of the brick.

[0140] Application of surface coatings

[0141] To increase the quality of the product and its resistance to moisture, after drying the product, we apply a water-repellent coating on the surface

[0142] The industrial application of the process of this invention involves the construction industry, and more specifically, the production of facade bricks with various designs and molds for the interior and exterior of the building, different types of sinks, counters, basins, toilets and other textured ceramic parts used in projects of any scope.

Claims

A low temperature manufacturing process for construction ceramic pieces with varied textures is proposed which includes the use of stone waste and mixing, molding, processing, texturing, sanding, drying and coating.According to claim 1, the utilized waste can be 45 to 90% by weight of all types of stone waste such as marble, granite, travertine, limestone and silica stone and it can be crushed waste from stone mines, quarries and waste mudstone.According to claim 1, in the stage of mixing and preparing the mortar, 3 types including self-compacting, fibrous and geopolymeric concrete compounds are used.According to claim 3, preparing the self-compacting concrete and geopolymer mixture includes pouring the combination in the mixer and mixing for 5 to 10 minutes. Then, the solution containing water and other additives such as superplasticizer and activator depending on the type of compound is added. For a unique appearance,all kinds of silica grains such as crushed glass grains can be added on the bottom of the mold or inside the mortar.According to claim 4, the raw materials for concrete composition can include all types of geopolymeric and self-compacting compounds to manufacture products such as bricks, wash basins, counters, toilets, sinks, and other decorative products with texture and a unique look.According to claim 4, the activator for geopolymer composition can include materials such as sodium silicate, sodium carbonate, sodium hydroxide, potassium hydroxide and lime. Depending on the type of composition, the percentage of activator can vary between 4 and 30% by weight of the binder.According to claim 1 and 3, for molding of self-compacting and geopolymeric mortar, ready mortar is poured into molds with different dimensions and shapes and placed under vibration or press. In the press molding method, the ratio of water to binder used is between 5 and 25% by weight and it is only used when pumice or sponge are not included in the product.According to claim 1 and 3, for molding of fiber-containing mortar, molding is done by vibrating or spraying concrete on the mold (depending on the shape of the mold, the amount of fibers in the composition and the required bending strength). After each layer is sprayed on the mold, the mortar is compressed by a roller to release the air. In this case, one can use fiber-free mortar for the first spraying layer.According to claim 1, in the molding stage, 2 methods are used to increase the adhesion of the brick product: using light aggregates (perlite, mineral or industrial pumice) in the mortar composition, or applying light aggregates or sponge blocks or foam concrete block mortar on the back of the brick.According to claim 9, in the first method, self-compacting, geopolymeric or fibrous mortar containing light aggregates with high fluidity, should be placed on the vibrating table for 1 to 3 minutes. Due to their low density, the aggregates move towards the surface of the mold with the vibration and help the product adhere better to the mortar during execution.According to claim 1, processing of the self-compacting mortar includes keeping it in a humid environment for 16 to 24 hours at a temperature of 20 to 35 degrees Celsius. Geopolymer mortar should be kept for 4 to 8 hours at a temperature of 30 to 120 degrees and in a better case at a temperature of 50 to 85 degrees Celsius. Also, for fibrous mortar, processing should be done in an environment with high humidity and for 1 to 7 days (depending on the desired final strength).According to claim 1, texturing includes applying a solution by spraying or flooding the surface of the product, which can include reactive components, surfactants, emission gas reducing components, gelling additives, and corrosion inhibitors.According to claim 12, the reactive component can be one or a combination of substances including amidosulfonic acid, alkanesulfonic acids such as methanesulfonic acid, ethanesulfonic acid, aminomethanesulfonic acid, etc.According to claim 12, the amount of reactive component in the composition depending on the type of composition used, the purpose and the required intensity of texturing can be between 1% and 100% by weight of the solution and in the optimal state it is between 5% and 50% by weight.According to claim 12, the surfactant can be one or a combination of materials including glycerin, ethylene glycol, diethylene glycol, triethylene glycol, alkylbenzene sulfonates, glycol ethers, butyl ether and their compounds, alkyl sulfonates. types of non-ionic surfactants, alcohols such as alcohol ethoxylate. The amount of surfactant addition can be above 0.01% by weight of the solution, and its ideal state is between 0.04% and 0.4% by weight.According to claim 12, the emission gas reducing component, depending on the composition of the tissue-forming solution, can be acrylamide, ammonia, carbonyl diamide, alpha acid amide, alkylurea or acrylamide copolymers. The amount can vary between 0.05 and 50%, and its ideal state is between 0.5 and 20% by weight of the solution.According to claim 12, the gelling additive can be one or a combination of materials including galactomannans such as caraya, xanthan, tractate, guar, kauri, as well as tara gum and modified guars such as hydroxypropyl guar. The amount can be between 0.05%, and its ideal state is between 0.1% and 0.7% by weight of the composition.According to claim 12, corrosion inhibitors can be one of the materials including sodium iodide, sodium methsilicate, potassium methsilicate, calcium methsilicate, phenylacridine, sulfonates and carboxylates. The amount can be between 0.01% and 3% by weight of the composition, and its ideal state is between 0.04% and 1% by weight of the composition.According to claim 1, coating the surface is done after drying the product and includes the application of materials including various resins such as epoxy resin, or surface protection materials such as waterproof, hydrophobic, anti-pollution and dust-proof materials.According to claim 19, to speed up the creation of the product's hydrophobic properties, hydrophobic substances can be applied when the product's temperature is from 50 to 120 degrees Celsius.

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