KR101145172B1 - Clay bricks and pavers, and method for manufacturing the same - Google Patents

Abstract

The present invention relates to a clay brick that can maintain various physical properties while providing various colors and natural feel to a clay brick including coal ash, and a method of manufacturing the same.

Description

Clay bricks and pavers, and method for manufacturing the same

The present invention relates to a clay brick and a method of manufacturing the same, and more particularly to a natural clay brick having a variety of colors and patterns and a method of manufacturing the same.

Clay bricks used as building materials or flooring materials are generally red, black, and gray in color and did not show natural and varied colors and patterns.

In particular, in recent years, the use of coal ash for energy saving, waste recycling, pollution prevention, and raw material replacement is not easy due to the lack of plasticity, which is difficult to extrude, and it is difficult to engrave the desired pattern. There was a problem with the beauty.

In addition, in order to solve the above problems, there was a case where glaze was applied to the surface of the clay brick, in which case there was a problem of losing the intrinsic texture of the clay brick.

Therefore, the present invention is to provide a clay brick and a method of manufacturing the same that can provide a natural and various colors and patterns to the clay brick containing coal ash.

In another aspect, the present invention is to provide a clay brick and a method of manufacturing the same, which can maintain a unique physical properties while providing a clay brick of various colors.

The present invention is a preferred first embodiment, (S1) step of preparing and extruding a body comprising 25 to 45% by weight of coal ash and 20 to 40% by weight of kaolin, 10 to 30% by weight of feldspar and 25 to 45% by weight of clay ; (S2) forming irregularities on the extruded body surface and spraying the water to the extent that water may be accumulated in the irregularities; (S3) 20 to 40% by weight of the dried brick powder powdered by drying the extruded body in (S1), 20 to 40% by weight of clay powder, 10 to 20% by weight of clear glass powder, 20 to 40% by weight of feldspar powder Spraying the powder containing powder% and 10 to 20% by weight of salt; And (S4) provides a method for producing a clay brick, characterized in that the firing while drying at 30 ~ 110 ℃ 45 ~ 55 hours while heating up to 1050 ~ 1150 ℃ for 25 to 32 hours.

In the first embodiment, the salt in step (S3) is 50 mesh or less, dry brick powder is 0.5mm or less, transparent glass powder and feldspar powder may be 100 mesh or less, clay powder may be 200 mesh or less.

In addition, the present invention is a second preferred embodiment, (S1) to prepare and extruding the base material containing 25 to 45% by weight of coal ash and 20 to 40% by weight of kaolin, 10 to 30% by weight of feldspar and 25 to 45% by weight of clay step; (S2) spraying and compressing the rock salt having a particle size of 3 ~ 10mm on the surface of the extruded brick column; (S3) 20 to 40% by weight of the dried brick powder powdered by drying the extruded body in (S1), 20 to 40% by weight of clay powder, 10 to 20% by weight of clear glass powder, 20 to 40% by weight of feldspar powder Spraying the powder containing powder% and 10 to 20% by weight of salt; And (S4) provides a method for producing a clay brick, characterized in that the firing while drying at 30 ~ 110 ℃ 45 ~ 55 hours while heating up to 1050 ~ 1150 ℃ for 25 to 32 hours.

In the first and second embodiments, the spraying of the powder in the step (S3) may be performed by a sieve of the W form.

In the first and second embodiments, (S3) may further include 3 to 15 parts by weight based on 100 parts by weight of the powdered powder, at least one selected from iron dioxide, titanium dioxide and aluminum oxide.

As a third preferred embodiment of the present invention, there is provided a clay brick produced by the above production method.

1 to 4 is a photograph of the clay brick produced by Examples 1 to 4 which is a preferred embodiment of the present invention.

Hereinafter, the present invention will be described in more detail.
In the above and the following descriptions, the term "clay brick" is generally used to encompass not only clay bricks used as walls, but also clay floor bricks used as flooring materials.

( S1 )step

The present invention first prepares a base material containing 25 to 45% by weight of coal ash and 20 to 40% by weight of kaolin, 10 to 30% by weight of feldspar and 25 to 45% by weight of clay to prepare a clay brick.

After mixing and pulverizing this, it is aged for 2 to 4 days and extruded in a vacuum drill to prepare a brick column-shaped molding.

(S2) step

Unevenness is formed on the extruded body surface and water is sprayed to dissolve the salt in the powder to be sprayed at a later stage. At this stage, the salt can be sprayed and pressed before spraying the unevenness and water. If spraying, water may not be sprayed.

In the case of forming irregularities on the surface of the body and spraying water, the irregularities only need to be formed, and the depth, size, shape and formation method thereof are not particularly limited. In order to form the unevenness, for example, unevenness may be formed using an uneven roller, and the method of forming the unevenness is not limited thereto.

The water is sprayed to such an extent that water may be accumulated in the unevenness. The water is sprayed to dissolve the salt at a later stage. The salt dissolves in water and undergoes a calcination process, forming a red or chocolate color on the base of the brick produced as it reacts with the ingredients of the base.

On the other hand, when spraying rock salt, the rock salt can be sprayed with a particle diameter of 3 ~ 10mm in consideration of the spraying effect, it can be pressed with a roller such as a pattern roller.

However, in the case of granite rock salt, the color of the brick is dissolved in water and melted during firing, so that the place where the rock salt was embedded can be cut and a shape similar to a volcanic crater can be formed, thereby causing unevenness.

( S3 )step

Next to the step (S2), 20 to 40% by weight of the dried brick powder powdered by drying the extruded body in (S1), 20 to 40% by weight of clay powder, 10 to 20% by weight of transparent glass powder, feldspar powder Spray powdered powder mixed with 20 to 40% by weight and 10 to 20% by weight of salt.

In the clay powder, the powder powder to be sprayed maintains adhesion during drying after drying and is soaked during firing, and the white powder is expressed. If it is more than 40% by weight is severe shrinkage due to the difference between the body and shrinkage rate is severe blonde, if less than 20% by weight lack of viscosity may occur desorption when drying.

The purpose of using the above-mentioned dry brick powder is to limit the desired color development when more than 40% by weight in order to adjust the coefficient of shrinkage and expansion of the color of the raw material powder on the surface, and less than 20% by weight of the shrinkage with the color raw material powder Desorption phenomenon tends to occur during the firing process due to the difference of the expansion coefficient.

The transparent glass powder acts as a raw material to form molten glass at low temperatures, and serves to induce bonding and reaction with the substrate. If the content exceeds 20% by weight, turbid color appears due to the sodium component present in the glass powder, which may degrade the quality of the product and impair the intrinsic properties of clay bricks.

The dry brick powder may be 0.149mm or less in consideration of the spraying effect, the transparent glass powder and feldspar powder may be 100 mesh or less (that is, 0.149mm or less) in consideration of the spraying effect, and the clay powder may also be considered in consideration of the spraying effect. It may be 200 mesh or less (ie, 0.074 mm or less).

The salt is dissolved in the water sprayed in the step (S2), and reacted with water vapor and decomposed during the sintering process to produce Na ₂ O. This component reacts with the base component to form a glass component while forming various amorphous shapes. Can be. The salt may be advantageous to include 10 to 20% by weight in consideration of shading expression, in consideration of the spraying effect can be used salt salt having a particle diameter of 50 mesh (0.3mm) or less, in particular, it is more preferable to use baked refined salt can do.

On the other hand, it may further include at least one selected from iron dioxide, titanium dioxide and aluminum oxide for color development, the content may further comprise 3 to 15 parts by weight based on 100 parts by weight of the powder in consideration of color.

The spraying of the powder powder may be performed by a W-type sieve. It is a sieve with a cross section of a W shape, the cross section of which is circular or elliptical. The sieve having a rectangular cross section or U-shaped sieve is actually spreading in a narrow and non-uniformly spreading area. The W-shaped sieve used in the present invention is capable of three-dimensional spraying on the lower and side surfaces, and has two spraying effects. Different colors can be produced efficiently by mixing during spraying, using the powder of the powder simultaneously. A sieve may be installed to vibrate automatically for uniform spraying so that the powder is sprayed regularly.

( S4 )step

The surface-treated body is dried and calcined, and the drying may be dried for 45 to 55 hours at 30 to 110 ℃, and then calcined while raising the temperature to 1050 to 1150 ℃ for 25 to 32 hours in the kiln.

In this way, the clay brick may be treated by treating the surface of the clay brick to have a beautiful appearance even if the clay brick is manufactured, and the clay brick and the clay floor brick, which can maintain the physical properties of the clay brick, and a manufacturing method thereof may be provided. .

Hereinafter, the present invention will be described in more detail with reference to Examples, but the scope of the present invention is not limited thereto.

≪ Example 1 >

40% by weight of coal ash, 25% by weight of kaolin, 25% by weight of clay, and 10% by weight of feldspar were mixed and pulverized, and the raw materials aged for three days were extruded in a vacuum drill.

20% by weight of clay powder (particle size of 200 mesh or less, 0.074 mm or less) after forming irregularities on the surface of the molded product by using an uneven roller on the conveyor belt for transporting the extruded molded product and spraying water in the form of a water film. , 20% by weight of dry brick powder (less than 100 mesh, 0.149mm or less), 10% by weight of transparent glass powder (less than 100 mesh, 0.149mm or less), 30% by weight of feldspar powder (less than or equal to 100 mesh, 0.149mm) Powdered powder containing 10 wt% of salt (particle size of 50 mesh or less, 0.3 mm or less) and 10 wt% of alumina oxide was sprayed through a circular W-shaped vibrating body.

Thereafter, the brick was cut to a size of 30 to 110 ° C. in a drying room for 50 hours, and then bricks were produced through a calcination process for 26 hours while heating up to 1100 ° C. in a 102m turnnel kiln.

<Example 2>

Except for spraying and pressing rock salt (particle size 3 ~ 10mm) on the surface of the brick column extruded in a vacuum drill in Example 1, and heated in a kiln to 1130 ℃ in the same manner as in Example 1 Clay bricks were prepared.

<Example 3>

40% by weight of coal ash, 25% by weight of kaolin, 25% by weight of clay, and 10% by weight of feldspar were mixed and pulverized, and the raw materials aged for three days were extruded in a vacuum drill.

On the conveyor belt for conveying the extruded molded article, the irregularities are formed on the surface of the molded article with a concave-convex roller, and then sprayed with water in the form of a water film, 20% by weight of clay powder and a dry brick powder (particle size of 100 mesh or less, 0.149mm or less) 20% by weight, transparent glass powder (particle size less than 100 mesh, 0.149mm or less), feldspar powder (particle size less than 100 mesh, 0.149mm or less) 27% by weight, salt (particle size less than 50 mesh, 0.3mm) Or less) 10 wt%, 10 wt% titanium dioxide and 3 wt% iron dioxide were sprayed through a circular W-shaped vibrating body.

Thereafter, the brick was cut to a size of 30 to 110 ° C. in a drying room for 50 hours, and then bricks were produced through a calcination process for 26 hours while heating up to 1100 ° C. in a 102m turnnel kiln.

<Example 4>

Except for spraying and pressing rock salt (particle size 3 ~ 10mm) on the surface of the brick column extruded in a vacuum drill in Example 3, and then calcined by heating up to 1130 ℃ in a kiln in the same manner as in Example 3 Clay bricks were prepared.

Comparative Example 1

After mixing and pulverizing 60% by weight of red clay and 40% by weight of red sand, the raw material aged for 3 days was extruded in a vacuum drill. When extruding, the mixture composed of 70% by weight of clay and 30% by weight of feldspar was sprayed on the surface of the extruded clay bricks by spraying a wet glaze prepared by ball milling at a ratio of 1: 1 with water for 24 hours. After cutting the furnace in a drying room for 30 hours at a temperature of 30 ~ 110 ℃ 50 ℃ in a 102m turnnel kiln was heated to 1130 ℃ while producing a brick through a 26-hour firing process.

Photograph of the brick produced in the embodiment is as shown in Figures 1 to 4, it can be seen that the clay brick treated by the surface treatment method of the present invention can produce a brick that can provide aesthetics while having a natural color.

In addition, the physical properties of the clay brick prepared by the surface treatment method of the present invention is shown in Table 1. (Test Method KS L 4201: 2008)

division
Test Items KS Standard Example 1 Example 2 Example 3 Example 4 Comparative Example 1 Absorption rate (%) below 10 7.8 7.2 8.0 7.4 9.1 Compressive strength (N / ㎡) 22.54 or more 31.69 35.16 30.58 36.07 25.65

Therefore, it can be seen that the clay brick of the present invention has sufficient strength and water absorption to be used as floor brick or building materials.

Claims (7)

(S1) preparing and extruding a body comprising 25 to 45% by weight of coal ash and 20 to 40% by weight of kaolin, 10 to 30% by weight of feldspar and 25 to 45% by weight of clay;
(S2) forming irregularities on the extruded body surface and spraying the water to the extent that water may be accumulated in the irregularities;
(S3) 20 to 40% by weight of the dried brick powder powdered by drying the extruded body in (S1), 20 to 40% by weight of clay powder, 10 to 20% by weight of clear glass powder, 20 to 40% by weight of feldspar powder Spraying the powder containing powder% and 10 to 20% by weight of salt; And
(S4) The method of producing a clay brick, characterized in that the baking while heating at 30 ~ 110 ℃ 45 ~ 55 hours while heating up to 1050 ~ 1150 ℃ for 25 to 32 hours.
The method of claim 1,
Clay brick manufacturing method further comprising the step of spraying and compressing the rock salt having a particle size of 3 ~ 10mm before the step (S2).
The method of claim 1,
In step (S3) the salt is 50 mesh or less, dry brick powder is 0.5mm or less, transparent glass powder and feldspar powder is 100 mesh or less, clay powder manufacturing method of clay brick characterized in that less than 200 mesh.
(S1) preparing and extruding a body comprising 25 to 45% by weight of coal ash and 20 to 40% by weight of kaolin, 10 to 30% by weight of feldspar and 25 to 45% by weight of clay;
(S2) spraying and compressing the rock salt having a particle size of 3 ~ 10mm on the surface of the extruded brick column;
(S3) 20 to 40% by weight of the dried brick powder powdered by drying the extruded body in (S1), 20 to 40% by weight of clay powder, 10 to 20% by weight of clear glass powder, 20 to 40% by weight of feldspar powder Spraying the powder containing powder% and 10 to 20% by weight of salt; And
(S4) The method of producing a clay brick, characterized in that the baking while heating at 30 ~ 110 ℃ 45 ~ 55 hours while heating up to 1050 ~ 1150 ℃ for 25 to 32 hours.
The method according to claim 1 or 4,
(S3) step of spraying the makeup powder is a clay brick manufacturing method, characterized in that is carried out with a sieve of the W-shape.
The method according to claim 1 or 4,
(S3) in the step of producing a clay brick, characterized in that further comprising 3 to 15 parts by weight based on 100 parts by weight of the powdered powder, at least one selected from iron dioxide, titanium dioxide and aluminum oxide.
Clay brick manufactured by the manufacturing method of claim 1 or 4.

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