Cow Dung Microsphere Homogenization for Closed-Pore Clay Bricks
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Solution Overview
Problem
Existing methods struggle to uniformly mix cow dung granules into clay bricks, leading to reduced compressive strength and increased energy consumption, as the density and fragility of cow dung granules make uniform distribution difficult, and existing processes are complex and inefficient.
Innovation Solution
A method and device that prepares pore-forming microspheres by mixing cow dung granules with a light-strength modifier, uniformly doping these microspheres into clay paste, and molding them into core and covering layers of clay bricks, followed by sintering to create a closed porous structure, using a homogenizing device with a kneading ejection part to ensure uniform distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If cow dung granules are added to reduce clay usage, then cost is reduced and sintering energy is reduced, but uniform mixing becomes difficult due to density difference and fragility
Solution Approach 1:
The cow dung granules are coated with clay slurry before mixing, creating a protective layer that prevents fragmentation during the mixing process. This preliminary coating action ensures that the granules maintain their integrity and distribute uniformly throughout the brick mixture, resolving the mixing uniformity problem while maintaining reduced clay usage
Solution Approach 2:
A clay slurry coating acts as an intermediary substance between the cow dung granules and the brick mixture. This coating layer facilitates uniform distribution by improving the interface between the lightweight granules and the denser clay matrix, preventing segregation while maintaining the reduced clay content formulation
2Device complexity
If conventional mixing methods are used, then process is simple, but cow dung granules are not uniformly distributed due to density difference
Solution Approach 1:
The granules are pre-coated with clay slurry to create a density-adjusted surface layer before mixing. This preliminary treatment modifies the effective density and surface properties of the granules, enabling them to mix uniformly with the clay matrix using conventional mixing equipment without requiring complex mixing systems
3Ease of manufacture
If cow dung is concentrated in certain places, then mixing is easier, but compressive strength is greatly reduced at those places
Solution Approach 1:
By coating each granule individually with clay slurry before mixing, the granules are pre-prepared to distribute evenly throughout the mixture. This prevents concentration in certain areas, ensuring uniform strength distribution while maintaining ease of mixing through the simplified coating-mixing process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves uniform mixing of cow dung granules, reducing clay usage without compromising brick strength, resulting in a closed porous structure that maintains compressive strength while decreasing clay consumption by 10-25%.
Implementation Method 1
sintering the clay brick blanks in a sintering kiln to obtain the clay bricks
Implementation Method 2
forming a closed porous structure during sintering that maintains brick strength
Data Source
AI summary
A pore-forming microsphere homogenizing device and method include steps of: firstly homogenizing the pore-forming microspheres made of the cow dung into the clay paste; secondly homogenizing the materials by using the kneading gear and the ejection cylinder rotating in opposite directions for kneading the clay paste while ejecting the pore-forming microspheres; and thirdly homogenizing the materials by using the telescopic kneading part and the ejection cylinder together for further kneading the clay paste while ejecting the pore-forming microspheres. With the foregoing processes, uniform and complete closed pores are uniformly distributed in the clay bricks, so that the strength of the clay bricks remains unchanged while clay usage is reduced.