AU2018299145A1 - Method for producing a brick - Google Patents

Method for producing a brick Download PDF

Info

Publication number
AU2018299145A1
AU2018299145A1 AU2018299145A AU2018299145A AU2018299145A1 AU 2018299145 A1 AU2018299145 A1 AU 2018299145A1 AU 2018299145 A AU2018299145 A AU 2018299145A AU 2018299145 A AU2018299145 A AU 2018299145A AU 2018299145 A1 AU2018299145 A1 AU 2018299145A1
Authority
AU
Australia
Prior art keywords
water
porous grains
binder
bed
porous
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
AU2018299145A
Inventor
Heinz Dullinger
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of AU2018299145A1 publication Critical patent/AU2018299145A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B20/00Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/0016Granular materials, e.g. microballoons
    • C04B20/002Hollow or porous granular materials
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/08Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding porous substances
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B20/00Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/10Coating or impregnating
    • C04B20/1055Coating or impregnating with inorganic materials
    • C04B20/1088Water
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/04Portland cements
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/24Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
    • C04B28/26Silicates of the alkali metals
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B40/00Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/06Inhibiting the setting, e.g. mortars of the deferred action type containing water in breakable containers ; Inhibiting the action of active ingredients
    • C04B40/0641Mechanical separation of ingredients, e.g. accelerator in breakable microcapsules
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16LPIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00Thermal insulation in general
    • F16L59/04Arrangements using dry fillers, e.g. using slag wool which is added to the object to be insulated by pouring, spreading, spraying or the like
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C1/00Building elements of block or other shape for the construction of parts of buildings
    • E04C1/40Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts
    • E04C1/41Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts composed of insulating material and load-bearing concrete, stone or stone-like material

Abstract

The invention relates to a method for producing a brick, which contains an insulating material body in a hollow chamber, which insulating material body is formed from a cured mixture of a fill of porous grains consisting of expanded particles of volcanic glass and a binder, the binder being a binder that cures by contact with water. Before the fill of porous grains is mixed with the still uncured binder, water is forced into the interior of the porous grains by means of a pressure difference.

Description

Method for producing a brick
The invention relates to a process for the production of a brick containing, within a hollow chamber, an insulation material body formed from porous grains of expanded particles of volcanic glass and a binder that binds them.
Volcanic glass in this context is materials of volcanic origin such as perlite, vermiculite, pitchstone or rhyolite that include a high proportion of SiCg as glassforming material and water of crystallization. Porous grains of expanded particles of volcanic glass are known to be formed by heating particles of volcanic glass to such an extent (over 700°C) that the glass-forming material components turn into a soft doughy material and are expanded by the evaporating trapped water of crystallization. The cooling solidifies the expanded doughy particles of material to form grains having a high proportion by volume of pores. This ideally forms grains that are not superficially fissured but have a surface with a vitreous, closed appearance, but below that have and a high (internal) pore content. Processes and apparatuses for the production of such particles expanded to form porous grains are disclosed, for example, by documents CN 201158620 Y, WO 2009/009817 Al, AT 504051 Al and EP 353860 A2.
Analogously to sand as that constituent of concrete which is referred to as admixture or as aggregate, as the case may be, a bulk material composed of particles of volcanic glass that have been expanded to form porous grains is also used in order to form an insulation material body with addition of a binder. An appropriate binder used - as in the case of concrete - may be a mixture of cement and water. According to the requirements, however, other binders may be used, for example waterglass or organic adhesives, or else cement mixtures containing a foam-forming component. The
WO 2019/010505 PCT/AT2018/000063
- 2 insulation bodies formed from bulk material from said porous grains and binders are typically used for thermal insulation in above-ground construction. As well as sheets that form a layer of a building, also obtainable for the purpose - for example under the name perlitefilled bricks - are bricks in which the cavities of a main alumina body are filled with insulation bodies formed from a cured bed of expanded perlite particles and binder .
AT 513933 Al describes a process for the binding of grains of expanded volcanic glass using a binder, wherein the binder itself is to be mixed from multiple liquid or pulverulent components or component groups. In order to avoid premature clumping of the binder during the mixing with the grains of expanded volcanic glass, in a first mixing operation, only the grains and such a portion of the components of the binder that is not curable on its own are mixed completely. Only in one or more later mixing operations are the remaining components of the binder mixed in. The finished mixture is cured in pressurecompacted form in a mold.
DE 10 2004 049 618 Al describes a hollow brick, the cavities of which are filled with a mixture comprising porous bulk material, for example expanded perlite. As well as the porous bulk material, the mixture at least also comprises water and a thickener. The thickener improves the ease of handling of the mixture during the filling of the cavities.
DE 10 2004 049618 Al describes a brick, the hollow chambers of which have been filled with insulation material based on a bulk material composed of porous grains, wherein the bulk material has been blended with water, thickener and preferably a hydrophobizing agent.
WO 2019/010505
PCT/AT2018/000063
DE 19844722 Al describes the composition of a lightweight construction mortar which is intended for factory production as a dry mortar mixture and is made up with water at the site of use and ultimately serves as a binder having good thermal insulation between the bricks of a wall. The dry mortar mixture comprises cement, air pore formers, and expanded perlite and expanded glass as lightweight admixtures .
DE 2417500 Al describes a process for producing relatively firm lightweight bricks of good porosity. A premixed dry mixture of a fine-grain sandy admixture and a pulverulent binder such as cement or lime hydrate is mixed in a further mixing operation with granular ice and compacted or tamped into a mold and cured therein.
DE 3304033 Al describes versions of a lightweight construction material consisting of expanded perlite as admixture and binder, wherein various binder mixtures also containing water are proposed. The components are mixed together including water and cured, partly in mold presses, partly under the action of water vapor.
EP 2915798 Al describes the production of a construction element based on expanded perlite. To a bed of porous grains formed by expanding perlite particles are added first water, then cement, then the mixture is filled into block molds, compacted by means of a compactor and ultimately cured.
WO 2008139180 Al describes the production of articles usable as thermal insulation, sound insulation or fire protection. A granular material composed of particles of expanded clay is impregnated with water up to three times its weight, then mixed with a binder, poured into a mold and cured.
WO 2019/010505
PCT/AT2018/000063
According to WO 9832713 Al, a lightweight material is formed from a bed of expanded perlite by adding hydrophobizing agent and - in an aqueous solution alkali metal silicates to the perlite.
The problem underlying the invention is that of providing a process for the production of a brick consisting of a main body comprising at least one hollow chamber and an insulation body which is the filling for at least one hollow chamber, wherein the insulation body consists of a solidified mixture, the base component of which having the greatest volume is a bed of porous grains formed by expansion of particles of volcanic glass. Compared to processes already known for the purpose, an improvement is to be achieved in that the operation of filling the hollow chamber is associated with lower complexity, and in that the insulation body may have higher propensity to diffusion and higher porosity, especially also when the porous grains themselves have a largely closed, nonfissured surface.
(A closed, non-fissured surface of the porous grains is desirable because this is associated with high mechanical strength and the absence of hazardous dusts.)
For the solution of the problem, the procedure is in accordance with the following sequence of steps:
a Water is injected into the interior of those porous grains that are formed by expansion of particles of volcanic glass.
b A bed of porous grains into which water has been injected is blended with a binder, so as to form a free-flowing mixture. The binder here is one is that cures on contact with water. Typically, a hygroscopic (i.e. water-absorbing) binder is used.
WO 2019/010505
PCT/AT2018/000063
- 5 c The free-flowing mixture formed in step b is introduced into hollow chambers of the main brick bodies.
d The mixture present in the hollow chambers is cured.
The injecting of water in step a requires there to be liquid water present at the outer surface of the porous grains and that this be under higher pressure than gas pressure in the interior of the porous grains. This required difference in pressure is preferably brought about in that a reduced pressure relative to ambient pressure is generated within the porous grains.
The reduced pressure can be generated in an autoclave. For this purpose, a bed of porous grains is first introduced into the working volume of the autoclave. Then the working volume is put under reduced pressure, i.e. air is sucked out of the otherwise closed working volume, until the pressure in the working volume is, for example, 0.3 bar lower than in the environment. As a result of the reduced pressure, gas escapes from the interior of the porous grains. After a couple of minutes, the working volume that was hitherto under reduced pressure is flooded with water. The reduced pressure within the porous grains sucks water into the porous grains. Once the bed of now water-enriched porous grains has been removed from the working volume of the autoclave, it can be dried a little, such that the outer surface of the porous grains is wholly or partly dry.
The generating of reduced pressure within the porous grains for the purpose of sucking water in can also be effected by rapid cooling. For this purpose, the bed of porous grains is preferably heated in a vessel in the dry state, for example to about 150°C, and then rapidly flooded with cold water. During the heating, as a result of thermal expansion, gas escapes from the interior of the porous grains. The reverse thermal expansion on
WO 2019/010505
PCT/AT2018/000063
- 6 flooding and hence cooling of the bed results in a reduced pressure within the porous grains. This reduced pressure sucks surrounding water into the pore volume of the porous grains. The bed thus formed can also be dried a little prior to the further processing.
For further processing, the bed of porous grains containing water is blended with binder. Typically, this binder is cement, for example commercial portland cement in the dry, pulverulent state. The volume ratio of bed of porous grains to cement powder here may, for example, be six to one. The drier the porous particles are, the more even the surface of the porous particles, and the finer the cement is ground, the less cement is required. The mixture formed from porous grains and binder is typically and ideally free-flowing and is just moist enough that it no longer visibly forms dust.
Immediately after the mixing operation, the mixture is introduced into hollow chambers of main brick bodies, typically consisting of fired clay. The now filled main brick bodies are left to stand, typically for at least 24 hours. The binder that cures in contact with water absorbs water during this time from the interior of the porous bodies and cures, which means that the mixture becomes a compact composite body, the desired insulation material body. This insulation material body is porous not just within those porous grains that have been formed through expansion of particles of volcanic glass, but also in the interstices between these porous grains.
The less binder has been mixed in, the higher the porosity achievable in the interstices between the porous grains. Very high porosity, which is generally desirable for construction-related physical reasons, however, is at the expense of the mechanical stability of the insulation material body. Optimal mixing ratios depend not only on the nature and characteristics of the components used but
WO 2019/010505
PCT/AT2018/000063 of course also on the desired properties of the insulation material body to be produced; they can at least be ascertained empirically in quite a simple manner - i.e. by specific experiments.
What is very advantageous about the process of the invention - aside from the high porosity of the insulation material body achievable thereby - is that the binder that cures by contact with water is in contact with water only when it is already present on the porous grains to be bound, and that, even then, only the amount of water directly required for the curing of the binder comes into contact with the binder. At no stage in the brick production are liquid water-binder mixtures present. This very significantly reduces the cleaning and maintenance complexity in the manufacturing plants compared to manufacturing plants in which liquid watercement mixtures are produced and processed, and it is possible to use simpler manufacturing plants.

Claims (5)

1. A process for the production of a brick containing, within a hollow chamber, an insulation material body composed of a cured mixture of a bed of porous grains of expanded particles of volcanic glass and a binder, where the binder is one that cures through contact with water, characterized in that water is injected into the interior of the porous grains by virtue of a difference in pressure prior to the mixing of the bed of porous grains with the as yet uncured binder.
2. The process as claimed in claim 1, characterized in that the binder used is one that is hygroscopic.
3. The process as claimed in claim 1 or 2, characterized in that the process steps of
- injecting water into the interior of the porous grains,
- forming a free-flowing mixture by blending a bed of porous grains into the interior of which water has been injected with the binder
- introducing the free-flowing mixture into hollow chambers of main brick bodies
- curing the mixture present in the hollow chambers are conducted successively in that sequence.
4. The process as claimed in claim 3, characterized in that there is a reduced pressure relative to ambient pressure within the porous grains during the injection of water into the interior of the porous grains .
WO 2019/010505
PCT/AT2018/000063
5. The process as claimed in any of claims 1 to 4, characterized in that water is injected into the interior of the porous grains by introducing a bed of porous grains into the working volume of an autoclave, then putting the working volume under reduced pressure and then flooding it with water.
The process as claimed in any of claims 1 to 4, characterized in that water is injected into the interior of the porous grains by heating a bed of porous grains in the dry state and then flooding it and cooling it with cold water.
The process as claimed in any of claims 1 to 6, characterized in that, after the flooding, a portion of the water is removed from the bed of porous grains .
8.
9.
The process as claimed in any of claims 1 to 7, characterized in that the binder is cement.
The process as claimed in any of claims 1 to 8, characterized in that the volcanic glass is rhyolite .
AU2018299145A 2017-07-11 2018-07-05 Method for producing a brick Abandoned AU2018299145A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
ATA290/2017 2017-07-11
ATA290/2017A AT520113B1 (en) 2017-07-11 2017-07-11 Method for making a tile
PCT/AT2018/000063 WO2019010505A1 (en) 2017-07-11 2018-07-05 Method for producing a brick

Publications (1)

Publication Number Publication Date
AU2018299145A1 true AU2018299145A1 (en) 2020-02-27

Family

ID=63363797

Family Applications (1)

Application Number Title Priority Date Filing Date
AU2018299145A Abandoned AU2018299145A1 (en) 2017-07-11 2018-07-05 Method for producing a brick

Country Status (4)

Country Link
EP (1) EP3652127A1 (en)
AT (1) AT520113B1 (en)
AU (1) AU2018299145A1 (en)
WO (1) WO2019010505A1 (en)

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3062752A (en) * 1958-05-02 1962-11-06 United States Gypsum Co Dimensionally stable expanded perlite and method for making the same
DE2417500A1 (en) * 1974-04-10 1975-10-23 Guenther Ziems Lightweight lime-sand bricks with internal cavities - mfd using ice instead of water in moulding mixtures
DE19844722A1 (en) * 1998-09-29 2000-03-30 Otavi Minen Ag Lightweight masonry mortar
DE102004049618B4 (en) * 2004-10-12 2007-08-30 Knauf Perlite Gmbh Hollow brick and use of a free-flowing mixture
GB0709046D0 (en) * 2007-05-11 2007-06-20 Ceramic Gas Products Ltd Method of forming an article
AT513933A1 (en) * 2013-02-12 2014-08-15 Horst Wustinger Method of joining grains of puffed volcanic glass

Also Published As

Publication number Publication date
AT520113B1 (en) 2019-06-15
AT520113A1 (en) 2019-01-15
WO2019010505A1 (en) 2019-01-17
EP3652127A1 (en) 2020-05-20

Similar Documents

Publication Publication Date Title
US4824811A (en) Lightweight ceramic material for building purposes, process for the production thereof and the use thereof
CN108726908B (en) Preparation method of artificial composite lightweight aggregate for foam concrete and artificial composite lightweight aggregate
US20160083295A1 (en) Thermally Insulating Aerogel Based Rendering Materials
KR101726589B1 (en) Expanded mortar and method for fabricating thereof
KR101737811B1 (en) Expanded mortar and method for fabricating thereof and repair material method
JP6681272B2 (en) Composition and non-combustible material
CN108863221A (en) A kind of foam concrete and preparation method thereof using artificial compounded lightweight aggregate
CN110407555A (en) A kind of chlorine oxygen magnesium foam fireproof concrete light wall composite material and preparation method thereof
CN102320804B (en) Non-bearing insulating brick
KR102129782B1 (en) Manufacturing Method of Pannel Using Foaming Ceramic Ball and Pannel Using Foaming Ceramic Ball thereby
KR101380171B1 (en) High durable cement for semi-rigid pavement having chloride resistant cement and Semi-rigid pavement method using filling the same in asphalt with vibrating
AU2018299145A1 (en) Method for producing a brick
KR102212696B1 (en) Lightweight aggregate and concrete panel using the same
RU2278847C1 (en) Composite structural heat-insulating compound and method of manufacture of such compound
JP4285675B2 (en) Aggregate for hardened cement and hardened cement
US8663386B2 (en) Dry cement mix for forming light concretes with low thermal conductivity, and concretes thus obtained
JP6681273B2 (en) Composition and non-combustible material
KR100603031B1 (en) Inorganic Lightweight Foam Composition and Method for Preparing the Same
KR102611738B1 (en) Method for manufacturing lightweight porous ceramic sintered body using vermiculite
EP2915789B1 (en) Construction element for acoustical and thermal insulation
JPH11189447A (en) Artificial lightweight aggregate, production of the same aggregate and lightweight concrete using the same aggregate
JP2003095715A (en) Aggregate for hardened cement, and hardened cement
HU209963B (en) Process for producing of porous materials from closed gascell graired silicates
US20220274874A1 (en) Process for producing a pore-containing granulate and a pore-containing artificial stone
Razak et al. Chemical cellulation technique for lightweight clay bricks

Legal Events

Date Code Title Description
MK4 Application lapsed section 142(2)(d) - no continuation fee paid for the application