CN105835223A - 一种硅酸钙夹心墙板生产方法 - Google Patents
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/14—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted
- B28B1/16—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted for producing layered articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
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- B28C5/006—Methods for mixing involving mechanical aspects
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28C7/00—Controlling the operation of apparatus for producing mixtures of clay or cement with other substances; Supplying or proportioning the ingredients for mixing clay or cement with other substances; Discharging the mixture
- B28C7/04—Supplying or proportioning the ingredients
- B28C7/0422—Weighing predetermined amounts of ingredients, e.g. for consecutive delivery
- B28C7/0431—Weighing predetermined amounts of ingredients, e.g. for consecutive delivery using a weighing belt or the like
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- B28C7/04—Supplying or proportioning the ingredients
- B28C7/06—Supplying the solid ingredients, e.g. by means of endless conveyors or jigging conveyors
- B28C7/067—Supplying the solid ingredients, e.g. by means of endless conveyors or jigging conveyors by means of stationary hoppers, chambers or bins from which the material is fed gravitationally, e.g. having agitating means therein
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
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- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
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Abstract
一种硅酸钙夹心墙板生产方法，原材料包括:石膏粉、炉渣颗粒、水泥组成干混料；干混料中配有聚苯乙烯颗粒、水、添加剂组成湿混料；添加剂中包括:羟丙基甲基纤维素、可分散乳胶粉、早强剂、减水剂、引气剂；生产系统由原料仓、聚苯乙烯颗粒仓、皮带秤、皮带机、水泵、搅拌机、模具车、模具组合、轻轨、添加剂库组成，其特征是：各料仓的出口均装有电脑控制的皮带秤并与皮带输送机对接，皮带输送机与搅拌机的进料端连接，干混料加聚苯乙烯颗粒和水及各种添加剂充分搅拌；灌入轻轨上装有硅酸钙面板的模具车上的模具组合中成形，并开始凝固；本发明能利废为宝、减轻工人劳动强度、产品是纯天然、绿色、健康、生态环保墙材。
Description
技术领域
本发明涉及一种硅酸钙夹心墙板生产方法，属建筑材料技术领城。
背景技术
高层建筑隔墙都用红砖、水泥砖块、较轻发泡砖等材料手工砌筑而成，再经几次抹灰找平，非常费工费力，造价高，工期长，砌体单位体积重，设计建筑力学受力费用高，钢材用量大，而且湿法施工不环保等缺点。
发明内容
本发明所要解决的第一个问题是提供一种硅酸钙夹心墙板生产方法。
本发明所要解决的第二个问题是提供一种硅酸钙夹心墙板皮带输送机生产系统。
为了解决上述第一个技术问题，本发明提供生产硅酸钙夹心墙板的原材料配方为: 石膏粉10-20％、炉渣颗粒30-40％(粒径在25mm以下)、425＃水泥50-60％组成干混料。
每吨干混料中配有2.4-2.6m3聚苯乙烯颗粒、加水24-26％、添加剂1.4—1.7% 组成湿混料。
炉渣用破碎机破碎, 最大粒径要求在25 mm以下；其本身质轻且具有一定强度，用做骨料，使颗粒积配达到理想比例。
添加剂1.4-1.7% 包括: 羟丙基甲基纤维素1.5-1.8kg、可分散乳胶粉0.6-0.8kg、早强剂9.5-11kg、减水剂600-700ml、引气剂1150-1300ml。
采用上述技术方案的硅酸钙夹心墙板生产方法，生产流程由一台电脑全程控制，由皮带秤将石膏粉料仓、炉渣颗粒料仓、水泥料仓中的物料，按配方中的比例控制每30套模具所需数量的物料，分别下料到皮带输送机中送往搅拌机，同时由电脑控制加入聚苯乙烯颗粒，并由人工加入各种添加剂，同时加水搅拌7-9分钟，搅拌后的湿混料要有很好的流动性，所得水混料灌入用硅酸钙装饰板做面板的模具中成型。
为了解决上述第二个技术问题，本发明还提供的一种硅酸钙夹心墙板皮带输送机配料生产系统，包括：石膏粉料仓、炉渣颗粒料仓、水泥料仓、聚苯乙烯颗粒仓、 聚苯乙烯原料仓、聚苯乙烯颗粒膨化机、 体积计量器、聚苯乙烯一次膨化料仓、蒸汽管、皮带秤、皮带输送机、水泵、模具组合、搅拌机、模具车、轻轨、添加剂库；其特征是：石膏粉料仓、炉渣颗粒料仓和水泥料仓的出口均装有电脑控制的皮带秤与皮带输送机对接，所述的皮带输送机与搅拌机的进料端连接。
聚苯乙烯原料仓的出口与聚苯乙烯颗粒膨化机连接，一次膨化料仓与所述的聚苯乙烯颗粒膨化机连接，所述的聚苯乙烯颗粒膨化机的出口与聚苯乙烯颗粒仓连接，所述的聚苯乙烯颗粒仓的出口通过电脑控制体积计量器与所述的搅拌机连接。
所述的聚苯乙烯颗粒膨化机连接有8-10kg/cm2高压蒸汽管。
搅拌机的进料端连接有电脑控制水泵的水泵出水管。
轻轨上设有至少1台模具车，所述的模具车上设有至少30套模具组合，所述的模具组合与所述的搅拌机的出口对接。
石膏粉、炉渣颗粒、水泥均为水凝性物质，灌模净置后开始凝固。
模具车由绞车运往初凝净置场区，24小时后由人工脱模；从模具车上放下平放叠码，每天施水，十天后将墙板横向折叠存放，利于养护；30天终凝期后入库，全生产过程在常温下进行。
聚苯乙烯颗粒料由电脑控制体积计量器给料。
加水量由电脑控制水泵按配比加水。
各种添加剂由人工添加。
模具车在进入灌模前由人工组合模具（装模），模具车的底板下安装四个轨道轮，便于在轻轨上行走，模具车的底盘上竖向安装模具的侧板和隔板，将硅酸钙板的正面（光滑的一面）紧贴侧板或隔板，每套模内插两块硅酸钙面板，每台模具车上安装30套模具，每排两套模具，共15排，组合完的模具车放在灌模台备用车位。
根据上述所提供的技术生产的硅酸钙夹心墙板与老式墙材比较具有以下进步：单位体积重量轻是砖墙砌体总重的1/5、加气混凝土砖的1/2；非常好的耐水性能，软化系数为0.83；抗压强度高达4.3-4.5mpa；抗裂性好，干燥收缩值为0.24mm/m；隔音性能（大于35-45/db）；防火性能(大于1.5-4h)；节能保温性好，导热系数小（1.7w/m2.k）,约为砼制品30%、粘土砖的35%；可加工性能好，产品在安装时可切割、可钉、可钻、可锯、管线埋设极为方便；墙材安装占地面积小，可增加房屋使用面积；材料来源广泛，利用固体废料炉渣颗粒，变废为宝；生产成本低，经济效益好，使用综合性价比高；而且可重复使用，拆装时均非常简便快捷。
综上所述，本发明是一种能降低高层建筑墙体单位体积的重量、减少高层建筑的总重而降低总的造价并能提高装饰速度、缩短工期、减少施工人员劳动强度、施工环保的硅酸钙夹心墙板生产方法，其生产简单快捷；产品配方无毒、无味、无放射性污染，是纯天然、绿色、健康、生态环保墙材。
附图说明
下面结合附图对本发明作进一步说明。
图1是本发明的工艺流程图。
图2是本发明设备系统示意图。
附图2中：1. 石膏粉料仓、2. 炉渣颗粒料仓、3.水泥料仓、4.聚苯乙烯颗粒仓、 5.聚苯乙烯原料仓、6. 聚苯乙烯颗粒膨化机、 7. 体积计量器、8. 聚苯乙烯一次膨化料仓、9. 蒸汽管、10. 皮带秤、11. 皮带输送机、12. 水泵、13. 模具组合、14. 搅拌机、15. 模具车、 16. 轻轨、17.添加剂库。
具体实施方式
下面结合附图和具体实施例对本发明作进一步说明。
具体实施例1。
用4毫米的普通硅酸钙装饰板做面板，中间填充料为水凝性物质，所述的水凝性物质配方以重量计为：石膏粉10%、炉渣颗粒30%、425＃水泥60%组成的干混料。
每吨干混料中配有2.6m3的聚苯乙烯颗粒，加水26％。
1.4% 的多种添加剂，所述的多种添加剂按每吨干混料计算：羟丙基甲基纤维素1.5kg、可分散乳胶粉0.6-kg、早强剂9.5kg、减水剂600ml、引气剂1150ml。
炉渣用破碎机破碎, 最大粒径要求在25 mm以下；其本身质轻而且具有一定强度，用做骨料，使颗粒积配达到理想比例。
具体实施例2。
用5毫米的普通硅酸钙装饰板做面板，中间填充料为水凝性物质，所述的水凝性物质配方以重量计为：石膏粉20%、炉渣颗粒30%、425＃水泥50%组成的干混料。
每吨干混料中配有2. 4m3的聚苯乙烯颗粒。
加水26％，以及1.7%的多种添加剂。
所述的1.7%的多种添加剂按每吨干混料计算：羟丙基甲基纤维素1.8kg、可分散乳胶粉0.8kg、早强剂11kg、减水剂700ml、引气剂1300ml。
炉渣用破碎机破碎, 最大粒径要求在25 mm以下；其本身质轻而且具有一定强度，用做骨料，使颗粒积配达到理想比例。
参见附图2，石膏粉料仓1、炉渣颗粒料仓2、水泥料仓3的出口端均装有电脑控制的皮带秤10并与皮带输送机11对接，皮带输送机11与搅拌机14的进料端连接。
聚苯乙烯原料仓5的出口与聚苯乙烯颗粒膨化机6连接，聚苯乙烯颗粒膨化机6连接有高温高压蒸汽管9，一次膨化料仓8与聚苯乙烯颗粒膨化机6连接，聚苯乙烯颗粒膨化机6的出口与聚苯乙烯颗粒仓4连接，聚苯乙烯颗粒仓4的出口通过电脑控制体积计量器7与搅拌机14连接。
搅拌机14的进料端连接有水泵12的出水管。
轻轨16上设有模具车15，模具车15上设有模具组合13，模具组合13与搅拌机14的出口对接。
工作时，电脑控制皮带秤10，将石膏粉料仓1、炉渣颗粒料仓2、水泥料仓3的物料按配方中的重量比例分别下料于皮带输送机11中，皮带输送机11将干混料送入搅拌机14。
聚苯乙烯原料仓5的原料进入聚苯乙烯颗粒膨化机6中并通入高温高压蒸汽9，进行第一次膨化后送入一次膨化料仓8中进行继续膨化，使颗粒直径达Φ4-5mm时（48小时）再次进入膨化机6中二次膨化，膨化颗粒进入聚苯乙烯颗粒仓4（二次膨化料仓）继续进行膨化颗粒直径达Φ6-8mm，室温维持到25℃左右。
聚苯乙烯颗粒仓4中的颗粒料由电脑控制体积计量器7定量将聚苯乙烯颗粒与干混料和水泥同时进入搅拌机14并由电脑控制水泵12加入定量的水，同时人工加入各种添加剂17，进行充分搅拌7-9分钟，将水混料灌入备好的模具组合13中成型。
模具车15将模具组合13从轻轨16上运送至初凝静置场中凝固，在常温下初凝24小时至中凝期拆模，出模后的成品条板叠码，每日施水养护，十天后将墙板横向折叠存放，利于养护；30天终凝期后入库，全生产过程在常温下进行。
条板规格一般长度2.44m，宽0.61 m，其厚度有60、75、90、120、150mm等多种规格。
以上所述为一个工艺生产流程，第二个工艺生产流程重复以上工作，周而复始的间隙式生产方式。
Claims (5)
1.一种硅酸钙夹心墙板生产方法，原材料包括: 石膏粉、炉渣颗粒、水泥组成干混料；干混料中配有聚苯乙烯颗粒、水、添加剂组成湿混料；添加剂中包括: 羟丙基甲基纤维素、可分散乳胶粉、早强剂、减水剂、引气剂；生产系统包括：石膏粉料仓、炉渣颗粒料仓、水泥料仓、聚苯乙烯颗粒仓、 聚苯乙烯原料仓、聚苯乙烯颗粒膨化机、 体积计量器、聚苯乙烯一次膨化料仓、蒸汽管、皮带秤、皮带输送机、水泵、模具组合、搅拌机、模具车、轻轨、添加剂库；其特征是：石膏粉料仓、炉渣颗粒料仓和水泥料仓的出口均装有电脑控制的皮带秤并与皮带输送机对接，所述的皮带输送机与搅拌机的进料端连接；聚苯乙烯原料仓的出口与聚苯乙烯颗粒膨化机连接，二次膨化后的聚苯乙烯颗粒进入聚苯乙烯颗粒仓，所述的聚苯乙烯颗粒仓的出口通过电脑控制体积计量器与所述的搅拌机连接；所述的聚苯乙烯颗粒膨化机连接有蒸汽管；所述的搅拌机的进料端连接有水泵出水管，电脑控制水泵加入定量的水，同时人工加入各种添加剂，充分搅拌7-9分钟，将水混料灌入备好的模具组合中成型；轻轨上设有模具车，所述的模具车上设有模具组合，所述的模具组合与所述的搅拌机的出口对接；模具车将模具组合从轻轨上运送至初凝静置场中凝固，在常温下初凝至中凝期拆模，出模后的成品条板叠码，每日施水养护，终凝期后入库。
2.根据权利要求1所述的一种硅酸钙夹心墙板生产方法，其特征是：组成干混料的配比为: 石膏粉10-20％、炉渣颗粒30-40％、水泥50-60％组成干混料。
3. 根据权利要求1或2所述的一种硅酸钙夹心墙板生产方法，其特征是：组成湿混料的配比为: 每吨干混料中配有2.4-2.6m3聚苯乙烯颗粒、加水24-26％、添加剂1.4—1.7% 组成湿混料。
4. 根据权利要求1或3所述的一种硅酸钙夹心墙板生产方法，其特征是：添加剂1.4-1.7% 包括: 羟丙基甲基纤维素1.5-1.8kg、可分散乳胶粉0.6-0.8kg、早强剂9.5-11kg、减水剂600-700ml、引气剂1150-1300ml。
5.根据权利要求1或3所述的一种硅酸钙夹心墙板生产方法，其特征是：湿混料搅拌7-9分钟，搅拌后的湿混料要有很好的流动性。
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