CN113754461B - 一种复合结构再生骨料烧结透水砖 - Google Patents
一种复合结构再生骨料烧结透水砖 Download PDFInfo
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Abstract
本发明公开了一种复合结构再生骨料烧结透水砖,属于新型建材技术领域。其为复合型盲孔烧结透水砖,由砖体和盲孔组成,盲孔沿砖底面顺着长边方向的中线均匀分布于砖体中下部基体中,盲孔孔口向下,孔盲端位于顶面向下约20‑30%砖厚度处。砖体由配方不同的上部过滤透水层与下部透水层组成,上、下层分别采用同一色泽或不同色泽,不同骨料粒度的成型料制成。上下层厚度比为1︰(7‑10)。与当前市场上流通的透水混凝土路面砖相比具有更加优异的抗冻性、透水性、耐磨性、防滑性,与现有的陶瓷透水砖相比,具有优异的透水、防滑、节材、节能特征,能够很好地实现海绵城市的铺装效果。
Description
技术领域
本发明属于新型建材技术领域,具体涉及到一种复合结构再生骨料烧结透水砖及其制备方法。
背景技术
为了改变当前在大雨、暴雨、特大暴雨时的城市“看海”模式,实现城镇化与自然环境的协调发展,海绵城市建设的理念已经深入人心。海绵城市将传统的“快排”模式转变为“渗、滞、蓄、滤、用、排”措施有机结合模式,希望能最大程度上减少城镇化开发建设大面积硬化给原自然水文特征和水生态环境带来的负面影响,从而实现对雨水的自然积存、渗透、净化和利用。而海绵城市的实现需要利用大量的高性能透水砖对现有广场和道路进行透水铺装改造,执行工程建设标准《砂基透水砖工程施工及验收规程CECS244︰2008》。
传统的铺地砖是烧结砖,主要成分为黄粘土或页岩,粘土烧结砖的大量生产会破坏耕地,所以各地都已基本禁粘禁实,转而发展新型建材,页岩砖也因为组织结构中多含微气孔,透水性能不好。目前,对道路进行透水铺装已经在多个城市展开,很多道路的人行步道已广泛采用新型透水砖,特别是在北方冬季结冰的城市已经广泛接受烧结透水砖。
常见透水砖为砖体组织结构中具有较多气孔的砖,包括普通混凝土透水砖、聚合物纤维增强混凝土透水砖、复合混凝土透水砖和烧结透水砖。普通的混凝土透水砖采用的主要组分骨料为普通碎石、钢渣和废弃混凝土再生骨料等,添加部分水泥和石膏为粘结剂压制后经养护、固化而成,其制备周期较长。聚合物纤维混凝土透水砖主要成分为石子、水泥和聚合物增强材料,增添的聚丙烯纤维使强度大大提高,但由于增添了聚丙烯纤维使得物料密实,造成透水性能下降。复合混凝土透水砖主要成分为彩色花岗岩、大理石石子,采用聚合物纤维或改性环氧树脂增强,外观多样化,但材料成本较高,其中的树脂在长时间的光照下会发生老化,性能急剧下降。典型的烧结透水砖是具有岩石性能的环境友好型无机非金属材料,具有较高的孔隙率和良好透水性,可有效缓解路面积水,并可有效隔绝噪音,具有良好的抗冻性、耐老化性能,具有良好的环境相容性,保水性能好,在雨季,大量铺设的陶瓷透水砖可以在内部孔隙中蓄存保有一定的水分,相当于在城市内建设了小型地下蓄水池,在天气干燥时段,随着气温的升高砖体中保有的水分释放蒸发,达到降低温度、保护植被、进行微环境调节的效果。但大量推广应用时,当前用于制备骨料的成分接近、耐温性能一致的废陶瓷砖、废洁具增量和存量有限,而一些企业采用以天然的粘土、长石、石英砂、滑石等原材料首先制成陶瓷块材再破碎制成骨料进而生产烧结透水砖的生产工艺,使得高品质的烧结透水砖生产成本和价格居高不下,限制了烧结透水砖的应用和推广。当前,天然的粘土、长石、石英砂、滑石等原材资源已经越来越匮乏,为了建设可持续发展的节约型社会,寻找烧结透水砖可以替代的骨料来源势在必行,具有紧迫性和必要性。
为了建设可持续发展社会、更好地发展循环经济、开发利用再生资源,节约天然砂石原材料特别是节约烧结透水砖所利用的粘土、长石、石英、滑石等天然原材料资源,迫切需要制备质量可靠、性能优异的相对低碳、节能、环保、利废的烧结透水砖。
磨料磨具生产企业以及磨具用户企业存在着大量的不合格品磨具和用后磨具废品的矿山,有待更加高效地开发利用。由于这些废弃陶瓷磨具尚有一定的残值,不应作为固废简单处理,但放置在企业厂区会占用较多的堆存空间,浪费昂贵的土地或仓储建筑面积,一定程度上还会影响企业厂区的整洁美观。而如果将这些废弃的陶瓷磨具破碎制成具有复合结构的再生骨料使用,可减少对不可再生天然砂石以及粘土、长石、石英、滑石等资源的消耗,是非常可行的途径。该复合结构骨料本身具有坚固性、再烧结性和多孔性,能够增强复合结构透水砖的透水性、过滤性、蓄排水性,并且其耐磨性、防滑性优越。以废弃陶瓷磨具破碎、筛分制成烧结透水砖用的高性能再生骨料是理想的资源化途径,能填补市场上烧结透水砖用高性能复合结构骨料的空白,这种复合结构再生骨料烧结透水砖是适合当前海绵城市建设用优良透水铺装材料。
发明内容
结合目前烧结透水砖的现状,本发明目的在于利用废弃陶瓷磨具破碎、筛分制备具有复合结构的高性能再生骨料,进而制备具有良好性能的复合结构烧结透水砖,用于广场或道路的透水铺装,促进海绵城市建设。
为实现上述目的,本发明将烧结透水砖设计成盲孔砖,该盲孔烧结透水砖为复合型砖,由砖体和盲孔组成,盲孔沿砖底面顺着长边方向的中线均匀分布于砖体中下部基体中,盲孔孔口向下,孔盲端位于顶面向下约20-30%砖厚度处。砖体由配方不同的上部过滤透水层与下部透水层组成,上、下部分别采用同一色泽或不同色泽,不同骨料粒度的成型料制成。
盲孔优选2~3个,为圆孔,孔直径之和约为砖底面长边的0.6倍,盲孔深度为砖厚度的70~80%。
所述上部过滤透水层和下部透水层的厚度比为1︰(7~10)。
所述盲孔烧结透水砖主材骨料为废弃陶瓷磨具破碎、筛分得到的具有复合结构的再生骨料,上层过滤透水层所用骨料的粒度细于下层透水层所用骨料粒度,上、下层成型料所用骨料分别优选20-30#和6-20#废弃陶瓷磨具破碎再生骨料。
其中,上层过滤透水层由如下材料混配而成:各组分以重量百分比计,
废弃陶瓷磨具破碎再生复合结构骨料80-90%,
专用陶瓷结合剂5-12%,
粘结剂糊精粉1.5-3%
湿润剂糊精液3~6%
无机色料0.5-3%;
下层透水层由如下材料混配而成:各组分以重量百分比计,
废弃陶瓷磨具破碎再生复合结构骨料80-94%,
专用陶瓷结合剂2-12%,
粘结剂糊精粉2-3%,
湿润剂糊精液2-5%。
其中,专用陶瓷结合剂选用低温型结合剂,各组分配比为:粘土粉10-20%、长石粉40-60%、硼玻璃粉20-50%。粘土粉、长石粉、硼玻璃粉粒度为100-320目。
制备方法:首先称取废弃陶瓷磨具破碎、筛分得到的再生复合结构骨料放入混料机,然后加入专用陶瓷结合剂、助剂混配成成型料,成型时对上、下层结构采用分别投料的二次投料法,分别梳料、刮平,然后整体一次性压制,脱模、干燥、烧成,制得烧结透水砖。
其中,成型料的混制采用双“S”混料锅,转速为150-200rad/min,总混合时间为6-15min。
其中,压制成型压力为4.0-6.0MPa,干燥温度为80-120℃,保温7-12h。烧制温度曲线为:首先以5-7℃/min升温速率加热到420℃,再以2-5℃/min升温速率加热到1000-1100℃,保温1.5-2h,然后停止加热,自然冷却得到烧结透水砖。
其中,色料为钴蓝、氧化铁红、铬绿和氧化铁黄无机色料中的一种。
其中,制备再生骨料使用的废弃陶瓷磨具主要为普通磨料材质的陶瓷磨具,具体包含白刚玉、棕刚玉、铬刚玉、单晶刚玉、绿碳化硅和黑碳化硅等,磨料粒度介于6-150#;
考虑到骨料对砖透水性以及强度的影响,本发明选用6#、20#和30#的筛网,将废弃陶瓷磨具再生骨料进行筛分,有效性为:20-30#再生骨料的颗粒度较小,堆积密度相对较大,以其为主材配制上部过滤透水层成型料,烧成后强度高、硬度大、耐磨性好、保形性较佳、边角不易脱落。 6-20#的再生骨料的颗粒度较大,以其为主材配制下部透水层,在成型烧结之后由于复合结构再生骨料本身具有磨料与结合剂和气孔组织,而且6-20#粒度段的粗大的再生骨料颗粒之间形不成最紧密堆积,留下较多孔隙,加入占主材份数为10-12%的专用陶瓷结合剂烧结时发生收缩,不足以填充骨料之间的孔隙,并且外加的占主材总质量2-3%的临时粘结剂糊精粉和2-5%的湿润剂糊精液一方面起湿润成型料,帮助成型料在压制成型时粘结到一起的辅助作用,同时由于其主要成分为无毒可被高温烧失的淀粉类有机物,烧失后在透水砖块体中留下很多微小的气孔组织。下部透水层更大的气孔率使透水砖具有更好的透水、疏水和保水作用。
本发明有益效果为:
本发明烧结透水砖采用磨具生产企业的过程废品或不合格品以及磨具加工车削下来的废渣和用户企业用后废弃陶瓷磨具为原料,经过鄂式破碎机、对辊破碎机等破碎、筛分得到不同粒度的再生骨料,作为烧结透水砖的骨料主材使用,为生产烧结透水砖开辟了骨料主材的来源,从消纳废弃陶瓷磨具的角度看,一定程度上减少了对磨具生产企业或用户企业库房面积的占用,降低了其运营成本,另一方面,将其开发为再生骨料烧结透水砖,相对比水泥基免烧透水砖具有更好的透水性、抗冻性、耐久性、较高的劈裂抗拉强度、耐磨性、防滑性,适用于海绵城市建设,具有更好的全寿命周期、绿色、低碳、节能特性,具有较高经济社会价值、生态环境效益良好。
本发明烧结透水砖经过高温1000-1100℃焙烧,具有优越的强度、硬度和抗冻性能,耐久性良好;
本发明烧结透水砖使用废弃陶瓷磨具再生复合结构骨料,因为废弃陶瓷磨具再生复合结构骨料本身具有大量微气孔,而成型、烧成后废弃陶瓷磨具再生骨料之间经结合剂桥连接部位还具有很多大大小小的气孔,使得透水砖具有良好的透水性、吸水性和保水性,经过正确施工应用的烧结透水砖地面在强降雨条件下不易造成积水;
进一步地,大量细小的上部过滤透水层气孔可过滤、吸附地面径流雨水中的有机物、杂质、重金属等有害物质,有利于生态环保;
进一步地,遍布砖机体大量的气孔具有微型蓄水池的作用,能蓄存雨水,使得透水砖具有一定的蓄水、保水、缓释水分性能,使透水砖铺装地面附近的动植物、微生物会被存留水汽滋养,有利于生态平衡。
为了保证强度,地砖通常设计为实体透水砖,其生产过程中原材料和烧成能耗成本较高。本发明采用盲孔设计结构,综合考虑其强度和耐久性,从整体上对盲孔大小及布局进行了设计,提高透水功能且不影响整体铺装效果,在常规铺装使用时,透水砖盲孔向下,上表面平整、连续、一体化,不会发生表面有孔洞、凹槽等砖体铺装地面时影响地面平整度、不利于清洁、过滤雨水、影响行走平坦的缺点。设有盲孔的烧结透水砖可以实现良好的透水效果,抗冻性优良、耐久性和强度良好,利于节材、节能,能很好地实现海绵城市的铺装效果。并且,以工业固废再生骨料制备高性能烧结透水砖,能够很好地消纳固废资源,具有环保、节约不可再生天然原材料资源,节约利用雨水资源、改善城市生态环境的社会效应。
附图说明
图1是本发明透水砖的制备工艺流程图;
图2是本发明透水砖结构示意图,其中:
(a)正常铺装时顶面在上底面在下的复合型盲孔烧结透水砖示意图,(b)底面在上顶面在下的复合型盲孔烧结透水砖示意图,(c)底面在上顶面在下的烧结透水面砖剖面结构示意图, 1- 砖体上部过滤透水层,2- 砖体下部透水层,3- 盲孔。
图3是本发明透水砖微观结构示意图,其中:
4-再生骨料内部磨粒(刚玉、碳化硅等);5-再生骨料内部气孔;6-再生骨料内部结合剂桥;7-再生骨料透水砖组织中再生骨料颗粒之间的结合剂桥;8-再生骨料透水砖组织中再生骨料颗粒、结合剂桥之间的气孔。
图4是本发明-再生骨料的形貌。
具体实施方式
为更好地解释本发明的目的、技术方案和优势,结合附图和实施例,对本发明进一步详细描述。所描述的附图说明和实施例仅用于说明本发明,不限制本发明的应用范围。
实施例1
如图2,本发明透水砖是一种复合型砖,由烧结透水砖砖体和盲孔(3)组成,砖体由上部过滤透水层(1)和下部透水层(2)组成,盲孔(3) 沿砖底面顺着长边方向的中线均匀分布于砖体中下部基体中,盲孔(3)孔口向下,孔盲端位于上部过滤透水层(1)所在砖顶面向下约20-30%砖厚度处。
盲孔优选2~3个,为圆孔,孔直径之和约为砖底面长边的0.6倍,盲孔深度为砖厚度的70~80%。
将该复合型砖设计为2种产品,即其一为上部过滤透水层(1)与下部透水层(2)采用不同色泽、不同骨料粒度成型料制成的具有不同微观组织结构的复合结构砖;其二为上部过滤透水层(1)与下部透水层(2)采用同一色泽、不同骨料粒度成型料制成的具有不同微观结构的复合型砖。
上层过滤透水层和下层透水层厚度之比为1︰7。
上层过滤透水层所用骨料的粒度细于下层透水层所用骨料粒度,上、下层成型料主材骨料分别优选20-30#和6-20#废弃陶瓷磨具破碎再生骨料。
其中,上层过滤透水层由如下材料混配而成:各组分以重量百分比计,
废弃陶瓷磨具破碎再生骨料84%,
专用陶瓷结合剂10%,
粘结剂糊精粉2%,
湿润剂糊精液3%,
氧化铁红色料1%;
下层透水层由如下材料混配而成:各组分以重量百分比计,
废弃陶瓷磨具破碎再生骨料90%,
专用陶瓷结合剂6%,
粘结剂糊精粉2%,
湿润剂糊精液2%。
其中,专用陶瓷结合剂选用低温型结合剂,各组分配比为:粘土粉20%、长石粉60%、硼玻璃粉20%。粘土粉、长石粉、硼玻璃粉粒度为100-320目。
如图1该烧结透水砖采用如下步骤制备而成:
步骤(1),制取再生骨料,将废弃陶瓷磨具破碎、筛分制成再生骨料,取粒度为6-20#(粒径5-0.85mm)和20-30#(粒径0.85-0.6mm)的再生骨料备用;
步骤(2),计算、称取各组分原材料:根据透水砖的规格尺寸、上部过滤透水层和下部透水层的厚度、上部过滤透水层和下部透水层成型料的密度、单重,计算每块透水砖上部过滤透水层和下部透水基层成型需要的投料量;根据需要成型透水砖的批量计算该成型批需要配制的成型料质量,根据成型料的配比计算、称取上部过滤透水层和下部透水层成型料配制各组分原材料。
步骤(3),混制成型料:根据步骤(2)的计算结果分别称取原材料、混制上部过滤透水层和下部透水层成型料。称量、加料和混料顺序为先将称取的再生骨料放入双”S”混料锅,开机运行加入糊精液湿润骨料,5min后加入专用陶瓷结合剂和糊精粉,继续混合运行3min,加入氧化铁红色料继续混合运行1min,将混合后的成型料移出搅拌锅、过筛,转移至成型料箱,困料以备成型,期间混料机转速为200rad/min。
步骤(4),分步投料、压制:根据步骤(2)的计算结果对于每块透水砖上部过滤透水层和下部透水基层成型需要的成型料投料量进行分别称量、分步投料,首先称取按步骤(3)混制的上部过滤透水层成型料,投入制砖模具内(此为第一次投料)梳均、刮平,然后称取按步骤(3)混制的下部透水基层成型料,投入制砖模具内(此为第二次投料),再次梳均、刮平(注意梳均时不可贯穿第一次投料刮平后的上部过滤透水层),然后,按照设定的压力进行成型压制(6.0MPa),压制成型时压机的上压头部位设有与盲孔数量、尺寸相对应一致的成型机构,使成型的砖坯在模具中的呈现为尚部砖体中有2~3个向上开口的圆形盲孔,然后脱模、干燥、烧成。
步骤(5),干燥、烧成:将步骤(4)成型的湿坯脱模后干燥、烧成,干燥温度为80℃保温12h,烧制温度曲线为1#:首先以6℃/min升温速率加热到420℃,再以5℃/min升温速率加热到1000℃,之后保温2h,停止加热、自然冷却,温度降至室温出炉。
步骤(6),检验、包装:对出炉的坯件根据指标要求进行检验,对合格品包装,得烧结透水砖成品。
实施例2
上层过滤透水层由如下材料混配而成:各组分以重量百分比计,
废弃陶瓷磨具破碎再生骨料81%,
专用陶瓷结合剂12 %,
粘结剂糊精粉 2 %,
湿润剂糊精液 3.5%,
氧化铁红色料1.5 %;
下层透水层由如下材料混配而成:各组分以重量百分比计,
废弃陶瓷磨具破碎再生骨料87 %,
专用陶瓷结合剂8%,
粘结剂糊精粉 2%,
湿润剂糊精液 3%。
其中,专用陶瓷结合剂选用低温型结合剂,各组分配比为:粘土粉20%、长石粉60%、硼玻璃粉20%。粘土粉、长石粉、硼玻璃粉粒度为100-320目。
所述上部过滤透水层和下部透水层的厚度比为1︰8。
制备工艺参数:
1)成型压力5MPa;2)烧制温度曲线为2#:首先以6℃/min升温速率加热到420℃,再以5℃/min升温速率加热到1050℃,之后保温2h,停止加热、自然冷却,温度降至室温出炉。
其他同实施例1。
实施例3
上层过滤透水层由如下材料混配而成:各组分以重量百分比计,
废弃陶瓷磨具破碎再生骨料80 %,
专用陶瓷结合剂12.5 %,
粘结剂糊精粉 2 %,
湿润剂糊精液4 %,
氧化铁红色料 1.5%;
下层透水层由如下材料混配而成:各组分以重量百分比计,
废弃陶瓷磨具破碎再生骨料 85%,
专用陶瓷结合剂 10 %,
粘结剂糊精粉 2%,
湿润剂糊精液 3%。
其中,专用陶瓷结合剂选用低温型结合剂,各组分配比为:粘土粉20%、长石粉60%、硼玻璃粉20%。粘土粉、长石粉、硼玻璃粉粒度为100-320目。
所述上部过滤透水层和下部透水层的厚度比为1︰10。
制备工艺参数:
1)成型压力4MPa;
2)烧制温度曲线为3#:首先以6℃/min升温速率加热到420℃,再以5℃/min升温速率加热到1100℃,之后保温2h,停止加热、自然冷却,温度降至室温出炉。
其他同实施例1。
根据具体实施方式,调整不同配比和工艺参数,共制得3种不同型号的烧结透水砖,依据GB/T25993-2010《透水路面砖和透水路面板》、GB/T9966.1-2001《天然饰面石材试验方法 第1部分:干燥、水饱和冻融循环后压缩强度试验》两个标准,其检测结果如下:
透水烧结路面砖的规格型号:200*125*55(mm)。
表1烧结透水砖性能检测结果
从上表数据可以看出,实施例1-3检测的性能指标均符合国家标准的指标要求,其中透水系数远远高于标准值,表明透水性优越。结合剂用量、成型压力、烧成温度制度等工艺参数的变化都会对产品的性能产生较大的影响,在生产实践中可根据产品性能要求进行设计,优选最佳配方及工艺参数。优选的,实例2制备的烧结透水砖性能更佳。
与当前市场上流通的水泥基免烧透水砖相比具有更好的抗冻性、耐磨性、防滑性、透水性,生命周期长,在其使用的全生命周期内具有绿色、节约利用雨水资源,综合社会效益高等特点。与烧结透水砖相比具有更好的透水性、蓄水性、节材、节能、利废等特征。
以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内所做的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (1)
1.一种烧结透水砖,其特征在于,由砖体和盲孔组成,盲孔沿砖底面顺着长边方向的中线均匀分布于砖体中下部基体中,盲孔孔口向下,孔盲端位于顶面向下20-30%砖厚度处;砖体由配方不同的上层过滤透水层与下层透水层组成,上、下部分别采用同一色泽或不同色泽,不同骨料粒度的成型料制成;
所述上层过滤透水层的成型料由如下组分混配而成,各组分以重量百分比计:
废弃陶瓷磨具破碎再生骨料80-90%,
专用陶瓷结合剂5-12%,
粘结剂糊精粉1.5-3%,
湿润剂糊精液3-6%,
无机色料0.5-3%;
所述下层透水层的成型料由如下组分混配而成:各组分以重量百分比计,
废弃陶瓷磨具破碎再生骨料80-94%,
专用陶瓷结合剂2-12%,
粘结剂糊精粉2-3%,
湿润剂糊精液2-5%;
其中,专用陶瓷结合剂选用低温型结合剂,各组分配比为:粘土粉10-20%、长石粉40-60%、硼玻璃粉20-50%;
所述盲孔选2-3个,为圆孔,孔直径之和为砖底面长边的0.6倍,盲孔深度为砖厚度的70-80%;
所述上层过滤透水层和下层透水层的厚度比为1︰(7-10);
烧结透水砖的制备方法包括:
首先称取废弃陶瓷磨具破碎、筛分得到的再生复合结构骨料放入混料机,然后加入专用陶瓷结合剂、助剂混配成成型料,成型时对上、下层结构采用分别投料的二次投料法,分别梳料、刮平,然后整体一次性压制,脱模、干燥、烧成,制得烧结透水砖;
其中,所述压制成型压力为4.0-6.0MPa,干燥温度为80-120℃,保温7-12h;所述烧成温度曲线包括,首先以5-7℃/min升温速率加热到420℃,再以2-5℃/min升温速率加热到1000-1100℃,保温1.5-2h,然后停止加热,自然冷却得到烧结透水砖;
所述上、下层成型料所用骨料分别选0.6~0.85mm和0.85~5mm废弃陶瓷磨具破碎再生骨料。
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