CN109265072A - 一种多层人造石及其制备方法 - Google Patents

一种多层人造石及其制备方法 Download PDF

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CN109265072A
CN109265072A CN201811128162.8A CN201811128162A CN109265072A CN 109265072 A CN109265072 A CN 109265072A CN 201811128162 A CN201811128162 A CN 201811128162A CN 109265072 A CN109265072 A CN 109265072A
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decorative layer
artificial stone
building stones
prefabricated
multilayer artificial
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CN109265072B (zh
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张国明
梁志坚
冼俭崧
肖怀贵
刘均贤
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Foshan Gaoming New Stone Co Ltd
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Foshan Gaoming New Stone Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
    • B29C67/242—Moulding mineral aggregates bonded with resin, e.g. resin concrete
    • B29C67/243—Moulding mineral aggregates bonded with resin, e.g. resin concrete for making articles of definite length
    • 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
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/005—Devices or processes for obtaining articles having a marble appearance
    • 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
    • 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
    • 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
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/30—Producing shaped prefabricated articles from the material by applying the material on to a core or other moulding surface to form a layer thereon
    • 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
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/08—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads
    • B28B11/0845—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads for smoothing
    • 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
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
    • B28B11/243—Setting, e.g. drying, dehydrating or firing ceramic articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
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    • B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
    • B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
    • B28B13/0215—Feeding the moulding material in measured quantities from a container or silo
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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
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0075—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects for decorative purposes
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/30—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being formed of particles, e.g. chips, granules, powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/002—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising natural stone or artificial stone
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/26—Carbonates
    • C04B14/28—Carbonates of calcium
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/18—Polyesters; Polycarbonates
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0866—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of several layers, e.g. sandwich panels or layered panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/025—Particulate layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/104—Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • B32B2307/4026—Coloured within the layer by addition of a colorant, e.g. pigments, dyes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2451/00—Decorative or ornamental articles
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/54—Pigments; Dyes
    • C—CHEMISTRY; METALLURGY
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    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
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    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
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    • C04B2111/542—Artificial natural stone
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
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Abstract

本发明涉及人造石板材技术领域，特别是一种多层人造石及其制备方法，一种多层人造石其从上至下依次包括：装饰层和底层，所述装饰层包括如下重量百分比的组分：装饰石料80％‑90％、不饱和聚酯树脂5％‑15％、偶联剂0.6％‑2％、固化剂0.7％‑1.2％和颜填料1％‑5％；所述底层包括如下质量百分比的组分：碳酸钙石料65％‑78％、不饱和聚酯树脂10％‑18％、偶联剂0.6％‑2％、固化剂0.7％‑1.2％和颜填料1％‑15％。所述制备方法将装饰层和底层分层制备再依次压合粘结形成一体，这样既可以保证所述多层人造石装饰效果和产品质量，又大大降低了生产成本。

Description

一种多层人造石及其制备方法
技术领域
本发明涉及人造石板材技术领域，特别是一种多层人造石及其制备方法。
背景技术
近年来人造石的生产和销售日渐成熟完善，人造石通常是指人造石实体面材、人造石石英石、人造石岗石等，人造石的类型繁多，不同类型的人造石，其成分也不尽相同。但是目前多部分的人造石英石的生产中，都是由70-95％的石英和树脂、色料及其他调节、粘接或固化剂等助剂，在真空、高温和高压下混合压制制造成一体的人造石的。人造石中石英砂和石英粉是通过采矿将矿产破碎而来，属于不可再生资源；如果人造石直接混合压制，不对其进行分层，为了保证良好的装饰效果和材料性能，人造石的主要石料只采用石英砂或石英粉，制造成本会很高。
发明内容
针对上述缺陷，本发明的目的在于提出一种将装饰层和底层分开制备再压紧粘结的多层人造石制备方法，所述多层人造石既保证了产品质量，又可大大降低生产成本。
为达此目的，本发明采用以下技术方案：
一种多层人造石，从上至下依次包括：装饰层和底层，所述装饰层和底层粘结形成一体；所述装饰层包括如下重量百分比的组分：装饰石料80％-90％、不饱和聚酯树脂5％-15％、偶联剂0.6％-2％、固化剂0.7％-1.2％和颜填料1％-5％；所述底层包括如下质量百分比的组分：碳酸钙石料65％-78％、不饱和聚酯树脂10％-18％、偶联剂0.6％-2％、固化剂0.7％-1.2％和颜填料1％-15％；更优的，所述底层下方还设有底部装饰层，所述装饰层和底层粘结形成一体；所述底部装饰层包括如下重量百分比的组分：装饰石料80％-90％、不饱和聚酯树脂5％-15％、偶联剂0.6％-2％、固化剂0.7％-1.2％和颜填料1％-5％。
在所述底层的两侧分别设置所述装饰层和底部装饰层，可使得所述多层人造石整体装饰效果更好，且所述底层两侧被包覆，可更大程度的保护所述底层，使其不易损坏，既简化了生产工艺，节省生产成本，也可以保证产品质量。
更优的，所述装饰石料为玻璃砂和/或石英石料。由于将两种不同种类的石料分层制备在压合粘结成一体，会由于不同层之间材质不同，导致固化时的应力不一致，容易导致最终固化得到的人造石发生变形甚至是开裂，因此现有技术中不建议采用该中方式，而本发明中为了解决这个问题，先是将各层中主要石料的百分比进行限定，使得不同材质的石料，在不同层中达到的材质参数接近，然后尽量利用相近比例的不饱和聚酯树脂、偶联剂、固化剂和颜填料组成的色浆树脂预制液来与石料混合，最终使得制备出的各层之间的材质参数相近，从而保证了在固化后得到的所述多层人造石不会因为各层之间应力过大而出现变形或开裂的问题；此外玻璃是可回收利用的资源，且有很好的装饰效果，大量应用于人造石，节约了矿石资源，又降低了人造石的生产成本，
更优的，所述装饰层或底部装饰层的厚度为0.5-1.5cm；所述底层厚度为0.5-2.5cm；装饰层和底部装饰层主要是为了装饰效果，因此从成本上考虑应偏薄，底层主要是碳酸钙，硬度、抗污和耐化学品性能相对差点，因此厚度应该偏厚，再考虑到要保证两层彼此之间的应力相近，因此将底部装饰层的厚度和底层的厚度限定再上述范围内才能保证所述多层人造石的装饰效果、质量参数达标且不变形和不开裂。
更优的，所述玻璃砂的大小为26-150目；所述石英石料为石英粉，所述石英粉的大小为200-450目；玻璃砂和石英石料的大小可以进一步提高所述人造玻璃石在制备过程中的流动性，便于压制平整不产生裂纹，可提高产品质量，因此进一步限定玻璃砂和石英石料的大小对提高所述人造玻璃石的质量有很大的意义。
用于制备如上所述的一种多层人造石的制备方法，其包括如下步骤：
A.将不饱和聚酯树脂加热至30-50℃，再加入偶联剂、固化剂和颜填料，搅拌至混合均匀，得到色浆树脂预制液；
B.将装饰石料和所述色浆树脂预制液加入料槽内，搅拌混合均匀，得到装饰层预制料；
C.将装饰层预制料下料平铺至模框中，预压紧，得到装饰层；
D.将碳酸钙石料和所述色浆树脂预制液倒入料槽中，搅拌混合均匀，得到底层预制料；
E.将底层预制料下料平铺至模框中的装饰层上表面，压紧，使得形成的底层和装饰层粘结形成一体，得到初级预制石板；
E1.将装饰层预制料下料平铺至模框中的底层上表面，压紧，得到预制石板；
F.将所述预制石板放入固化炉中固化后，抛光装饰层表面，得到所述多层人造石。
需先通过预压制备所述装饰层，是为了使得装饰石料层致密，后期加入底层预制料后，再进行压制，碳酸钙石料不会穿入或穿出装饰层中，进而保证了所述装饰层的装饰效果。
更优的，所述步骤A中搅拌混合方式为高速搅拌1-2分钟；高速搅拌时搅拌机的工作频率为40-60赫兹；所述步骤B和D中搅拌混合方式为低速搅拌4-6分钟，低速时搅拌搅拌机的工作频率为10-20赫兹。搅拌机在不同的制备步骤是工作频率不一样，再结合具体的搅拌时间，可以保证搅拌效果能使得装饰石料的流动性更好，且又不会应为搅拌过度破坏了色浆树脂预制液的包裹粘性，从而保证了装饰石料不会掉落，装饰层表面平整，也使得制备过程更加高效精准，产品质量更高。
更优的，所述预压紧是压力范围为0.1-0.3Mpa，所述压紧的压力范围为1-2Mpa；由于所述多层人造石中各层之间是采用了压紧粘结的方式，但是由于各层材质有差异，且厚度也有差异，因此在不同压制粘结阶段需要采用不同的压力进行压紧或预压紧，以避免装饰层或底部装饰层装饰效果收到破坏，或这是所述多层人造石出现变形或开裂。
更优的，所述步骤F中所述固化炉对所述预烧板进行固化的温度范围为：70-110℃；由于所述多层人造石是有各种不同石料层压制粘结而成的，在固化时需要对温度进行精准控制，以避免不同材质的各层在固化炉中进行固化时出现应力变化过快或过慢，导致各层之间应力差异过大，进而影响质量的情况出现。
本发明提出一种所述多层人造石及其制备方法，该制备方法是将装饰层和底层分层制备再压合粘结形成一体，由于底层主要是由更低廉的碳酸钙制成，价格更贵的装饰石料则更大程度的应用在铺设外露在外部的装饰层中，这样既可以保证所述多层人造石装饰效果和产品质量，且可以使得每层的制备石料单一控制更加简单准确，生产成本也可以大大的降低。
具体实施方式
下面通过具体实施方式来进一步说明本发明的技术方案。
一种多层人造石，其从上至下依次包括：装饰层和底层，所述装饰层和底层粘结形成一体。
其中所述装饰层包括如下组分：装饰石料、不饱和聚酯树脂、偶联剂、固化剂和颜填料；所述底层包括如下种类的组分：
碳酸钙石料、不饱和聚酯树脂、偶联剂、固化剂和颜填料。
所述底部装饰层包括如下种类的组分：碳酸钙石料、不饱和聚酯树脂、偶联剂、固化剂和颜填料。
其制备方法为如下：
A.将不饱和聚酯树脂加热至30-50℃，再加入偶联剂、固化剂和颜填料，高速搅拌1-2分钟，高速搅拌时搅拌机的工作频率为40-60赫兹，得到色浆树脂预制液；
B.将装饰石料和所述色浆树脂预制液加入料槽内，低速搅拌4-6分钟，低速时搅拌搅拌机的工作频率为10-20赫兹，得到装饰层预制料；
C.将装饰层预制料下料平铺至模框中，预压紧，压力范围为0.1-0.3Mpa，得到装饰层；
D.将碳酸钙石料和所述色浆树脂预制液倒入料槽中，低速搅拌4-6分钟，低速时搅拌搅拌机的工作频率为10-20赫兹，得到底层预制料；
E.将底层预制料下料平铺至模框中的装饰层上表面，压紧，压力范围为1-2Mpa，使得形成的底层和装饰层粘结形成一体，得到预制石板；
F.将所述预制石板放入固化炉中固化后，抛光装饰层表面，得到所述多层人造石。
具体的，所述装饰石料为大小为80目的玻璃砂和/或大小为325目石英石料；预压紧是通过预压辊压紧的方式；所述步骤F中所述固化炉对所述预烧板进行固化的温度范围为：70-110℃。
根据上述组分和制备方法，调整各组份之间的配比，获得不同的具有装饰层和底层的所述多层人造石，并对产品进行对比，具体如下表1：
表1：具有所述装饰层和底层的所述多层人造石的实施例汇总表
一种多层人造石，其从上至下依次包括：装饰层、底层和底部装饰层，所述装饰层、底层和底部装饰层粘结形成一体。
其中所述装饰层包括如下组分：装饰石料、不饱和聚酯树脂、偶联剂、固化剂和颜填料；所述底层包括如下种类的组分：
碳酸钙石料、不饱和聚酯树脂、偶联剂、固化剂和颜填料。
所述底部装饰层包括如下种类的组分：碳酸钙石料、不饱和聚酯树脂、偶联剂、固化剂和颜填料。
其制备方法为如下：
A.将不饱和聚酯树脂加热至30-50℃，再加入偶联剂、固化剂和颜填料，高速搅拌1-2分钟，高速搅拌时搅拌机的工作频率为40-60赫兹，得到色浆树脂预制液；
B.将装饰石料和所述色浆树脂预制液加入料槽内，低速搅拌4-6分钟，低速时搅拌搅拌机的工作频率为10-20赫兹，得到装饰层预制料；
C.将装饰层预制料下料平铺至模框中，预压紧，压力范围为0.1-0.3Mpa，得到装饰层；
D.将碳酸钙石料和所述色浆树脂预制液倒入料槽中，低速搅拌4-6分钟，低速时搅拌搅拌机的工作频率为10-20赫兹，得到底层预制料；
E.将底层预制料下料平铺至模框中的装饰层上表面，压紧，压力范围为1-2Mpa，使得形成的底层和装饰层粘结形成一体，得到初级预制石板；
当增设有所述底部装饰层时，还包括步骤E1.将装饰层预制料下料平铺至模框中的底层上表面，压紧，压力范围为1-2Mpa，得到预制石板；
F.将所述预制石板放入固化炉中固化后，抛光装饰层表面，得到所述多层人造石。
具体的，所述装饰石料为大小为80目的玻璃砂和/或大小为325目石英石料；预压紧是通过预压辊压紧的方式；所述步骤F中所述固化炉对所述预烧板进行固化的温度范围为：70-110℃。
根据上述组分和制备方法，调整各组份之间的配比，获得不同的具有装饰层、底层和底部装饰层的所述多层人造石，并对产品进行对比，具体如下表2：
表2：具有所述装饰层、底层和底部装饰层的所述多层人造石的实施例汇总表
从上表1和2中实施例1-32可以看出，所述多层人造石各层的组分组百分比超出限定范围时，生产出的产品的表面要么是装饰效果差，要么是发生了石板本体的变形，甚至还有开裂问题。
本发明提出的一种所述多层人造石及其制备方法，该制备方法是将装饰层、底层和底部装饰层分层制备再压合粘结形成一体，由于底层主要是由更低廉的碳酸钙制成，价格更贵的装饰石料则更大程度的应用在铺设外露在外部的装饰层中，这样既可以保证所述多层人造石装饰效果和产品质量，且可以使得每层的制备石料单一控制更加简单准确，生产成本也可以大大的降低。
以上结合具体实施例描述了本发明的技术原理。这些描述只是为了解释本发明的原理，而不能以任何方式解释为对本发明保护范围的限制。基于此处的解释，本领域的技术人员不需要付出创造性的劳动即可联想到本发明的其它具体实施方式，这些方式都将落入本发明的保护范围之内。

Claims (9)

1.一种多层人造石，其特征在于，从上至下依次包括：装饰层和底层，所述装饰层和底层粘结形成一体；
所述装饰层包括如下重量百分比的组分：
装饰石料80％-90％、不饱和聚酯树脂5％-15％、偶联剂0.6％-2％、固化剂0.7％-1.2％和颜填料1％-5％；
所述底层包括如下质量百分比的组分：
碳酸钙石料65％-78％、不饱和聚酯树脂10％-18％、偶联剂0.6％-2％、固化剂0.7％-1.2％和颜填料1％-15％。
2.根据权利要求1所述的一种多层人造石，其特征在于，所述底层下方还设有底部装饰层，所述装饰层和底层粘结形成一体；所述底部装饰层包括如下重量百分比的组分：装饰石料80％-90％、不饱和聚酯树脂5％-15％、偶联剂0.6％-2％、固化剂0.7％-1.2％和颜填料1％-5％。
3.根据权利要求2所述的一种多层人造石，其特征在于，所述装饰石料为玻璃砂和/或石英石料。
4.根据权利要求2所述的一种多层人造石，其特征在于，所述装饰层或底部装饰层的厚度为0.5-1.5cm；所述底层厚度为0.5-2.5cm。
5.根据权利要求2所述的一种多层人造石，其特征在于，所述玻璃砂的大小为26-150目；所述石英石料为石英粉，所述石英粉的大小为200-450目。
6.用于制备如权利要求1-5中任意一项所述的一种多层人造石的制备方法，其特征在于，包括如下步骤：
A.将不饱和聚酯树脂加热至30-50℃，再加入偶联剂、固化剂和颜填料，搅拌至混合均匀，得到色浆树脂预制液；
B.将装饰石料和所述色浆树脂预制液加入料槽内，搅拌混合均匀，得到装饰层预制料；
C.将装饰层预制料下料平铺至模框中，预压紧，得到装饰层；
D.将碳酸钙石料和所述色浆树脂预制液倒入料槽中，搅拌混合均匀，得到底层预制料；
E.将底层预制料下料平铺至模框中的装饰层上表面，压紧，使得形成的底层和装饰层粘结形成一体，得到初级预制石板；
E1.将装饰层预制料下料平铺至模框中的底层上表面，压紧，得到预制石板；
F.将所述预制石板放入固化炉中固化后，抛光装饰层表面，得到所述多层人造石。
7.根据权利要求6所述的一种制备方法，其特征在于，所述步骤A中搅拌混合方式为高速搅拌1-2分钟；高速搅拌时搅拌机的工作频率为40-60赫兹；所述步骤B和D中搅拌混合方式为低速搅拌4-6分钟，低速时搅拌搅拌机的工作频率为10-20赫兹。
8.根据权利要求6所述的一种制备方法，其特征在于，所述预压紧是压力范围为0.1-0.3Mpa，所述压紧的压力范围为1-2Mpa。
9.根据权利要求6所述的一种制备方法，其特征在于，所述步骤F中所述固化炉对所述预烧板进行固化的温度范围为：70-110℃。
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CN117400406A (zh) * 2022-12-21 2024-01-16 湖北燕沙建材科技有限公司 一种石英石板的生产工艺
CN117400406B (zh) * 2022-12-21 2024-06-07 湖北燕沙建材科技有限公司 一种石英石板的生产工艺

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