CN113788647A - Lightweight artificial quartz stone and production process thereof - Google Patents
Lightweight artificial quartz stone and production process thereof Download PDFInfo
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- CN113788647A CN113788647A CN202111147089.0A CN202111147089A CN113788647A CN 113788647 A CN113788647 A CN 113788647A CN 202111147089 A CN202111147089 A CN 202111147089A CN 113788647 A CN113788647 A CN 113788647A
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- 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
- 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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- A—HUMAN NECESSITIES
- A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
- A01N—PRESERVATION OF BODIES OF HUMANS OR ANIMALS OR PLANTS OR PARTS THEREOF; BIOCIDES, e.g. AS DISINFECTANTS, AS PESTICIDES OR AS HERBICIDES; PEST REPELLANTS OR ATTRACTANTS; PLANT GROWTH REGULATORS
- A01N59/00—Biocides, pest repellants or attractants, or plant growth regulators containing elements or inorganic compounds
- A01N59/16—Heavy metals; Compounds thereof
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
- B32B13/02—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
- B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B13/12—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
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- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
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- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
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- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/10—Interconnection of layers at least one layer having inter-reactive properties
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/34—Silicon-containing compounds
- C08K3/36—Silica
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K7/00—Use of ingredients characterised by shape
- C08K7/22—Expanded, porous or hollow particles
- C08K7/24—Expanded, porous or hollow particles inorganic
- C08K7/28—Glass
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- 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
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/546—Flexural strength; Flexion stiffness
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- B32B2307/00—Properties of the layers or laminate
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- 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
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Abstract
The invention aims to provide a lightweight artificial quartz stone and a production process thereof, and the lightweight artificial quartz stone comprises an artificial board prefabricated material and a lightweight layer prefabricated material which are formed together; the artificial board prefabricated material comprises the following components in parts by weight: 100-150 parts of white cement, 20-90 parts of silica powder, 300 parts of quartz dust, 50-100 parts of stone aggregate, 30-36 parts of water, 1.5-3 parts of water reducing agent, 70-80 parts of resin, 5-10 parts of color paste and 0.1-0.2 part of curing agent; the lightweight layer prefabricated material comprises, by weight, 6-10 parts of hollow glass microspheres, 20-60 parts of silica powder and 30-70 parts of resin. The invention provides a processing technology of artificial quartz stone, which comprises the following steps: s1, preparing a prefabricated material for the artificial board, wherein the prefabricated material comprises raw materials of 100 portions of white cement, 20 to 90 portions of silica powder, 300 portions of quartz dust, 50 to 100 portions of stone aggregate, 30 to 36 portions of water, 1.5 to 3 portions of water reducing agent, 70 to 80 portions of resin, 5 to 10 portions of color paste and 0.1 to 0.2 portion of curing agent. Adding the raw materials into mixing equipment, and mixing at normal temperature to obtain an artificial board prefabricated material for later use.
Description
Technical Field
The invention relates to the field of artificial quartz, in particular to light artificial quartz and a production process thereof.
Background
With the development of modern architectural decoration industry, the requirements of people on environmental decoration are more extensive. Many precious products on the earth are crazy to be mined and glancing, and a large amount of non-renewable materials face exhaustion and disappearance. The production of the color artificial stone as a renewable material is a product of the trend of environment beautification in this era. Particularly, the product has the characteristics of rich colors, various shapes, durability, simple processing and low price, and simultaneously has the characteristics of greenness, energy conservation and environmental protection, thereby completely meeting the high standards and high requirements of various material effects of architectural decoration and environmental beautification at present.
The artificial quartz stone is composed of more than 80% of natural quartz, about 10% of pigment, resin and other additives for regulating bonding and curing. The plate is processed by a production method of negative pressure vacuum, high frequency vibration molding, heating and curing (the temperature is determined according to the type of curing agent), and the plate has the characteristics of hard texture (Mohs hardness of 5-7), compact structure (density of 2.3 g/cubic centimeter) and incomparable wear resistance, pressure resistance, high temperature resistance, corrosion resistance, seepage prevention and the like compared with other decorative materials.
Among the prior art, in order to solve traditional rostone product line maldistribution, the poor problem of outward appearance, light materials such as similar wood flour, vermiculite powder, pearlite powder can be added in some rostone formulas and add in the rostone formula, but in the actual preparation product process, because the compatibility of this type of granule and thick liquids is poor, thereby can suspend on the thick liquids upper strata after leading to this type of light thick liquids to mix, thereby it is little to lead to the upper density to appear in the panel of artificial quartz production, the big defect of lower floor density, light type thick liquids maldistribution promptly, lead to stone material poor stability.
Disclosure of Invention
The invention aims to provide a lightweight artificial quartz stone and a production process thereof, so as to solve the problems in the background technology.
In order to achieve the purpose, the invention provides the following technical scheme:
a light artificial quartz stone comprises an artificial board prefabricated material and a light layer prefabricated material which are formed together;
the artificial board prefabricated material comprises the following components in parts by weight: 100-150 parts of white cement, 20-90 parts of silica powder, 300 parts of quartz dust, 50-100 parts of stone aggregate, 30-36 parts of water, 1.5-3 parts of water reducing agent, 70-80 parts of resin, 5-10 parts of color paste and 0.1-0.2 part of curing agent;
the lightweight layer prefabricated material comprises, by weight, 6-10 parts of hollow glass microspheres, 20-60 parts of silica powder and 30-70 parts of resin.
The invention provides a processing technology of artificial quartz stone, which comprises the following steps:
s1, preparing a prefabricated material for the artificial board, wherein the prefabricated material comprises raw materials of 100 portions of white cement, 20 to 90 portions of silica powder, 300 portions of quartz dust, 50 to 100 portions of stone aggregate, 30 to 36 portions of water, 1.5 to 3 portions of water reducing agent, 70 to 80 portions of resin, 5 to 10 portions of color paste and 0.1 to 0.2 portion of curing agent. Adding the raw materials into mixing equipment, and mixing at normal temperature to obtain an artificial board prefabricated material for later use.
S2, preparing a light-weight layer prefabricated material, namely taking 6-10 parts of hollow glass microspheres, 20-60 parts of silica powder and 30-70 parts of resin as raw materials, adding the raw materials into mixing equipment, and mixing at normal temperature to prepare the light-weight layer prefabricated material for later use.
S3, performing molding and curing on the artificial board prefabricated material, taking out the stone slab to prepare a mold frame, laying the artificial board prefabricated material prepared in the step S1 in the mold frame and forming a bottom layer, performing vacuum vibration molding on the transverse frame and the bottom layer laid material, vacuumizing to separate out air in the bottom layer artificial board prefabricated material, and matching vibration to realize primary surface leveling, wherein the vacuum degree is kept to be lower than 70 mmHg; and curing the bottom artificial board preform formed by vacuum vibration molding through high-temperature steam, wherein the curing is carried out for 1min under the vacuum degree lower than 50 mmHg.
S4, stacking and molding the light-weight layer prefabricated material, pouring the light-weight layer prefabricated material prepared in the step S2 on the upper layer of the prepared solidified artificial board prefabricated material, paving the light-weight layer prefabricated material, and performing vacuum vibration molding on the light-weight layer prefabricated material to level the surface of the light-weight layer prefabricated material; and solidifying the leveled artificial board prefabricated material and the light-weight layer prefabricated material positioned on the upper layer of the artificial board prefabricated material.
And S5, repeating the steps S3 and S4, enabling the plate to form a layer alternating structure of artificial board prefabricated materials and light layer prefabricated materials, enabling the uppermost layer of the plate to be artificial board prefabricated materials, namely the uppermost layer and the lowermost layer of the plate blank to be artificial board prefabricated materials, and enabling the middle layer to be the artificial board prefabricated materials and the light layer prefabricated materials to be alternately stacked, and finally manufacturing the plate blank meeting the thickness requirement.
S6: and (3) curing the plate blank, namely, performing final curing on the plate blank prepared in the step S5 at high temperature and high pressure, and curing for 5 to 10 hours in an autoclave at 7.0 to 10.0 bar and at the temperature of between 140 and 200 ℃ to form the artificial stone plate semi-finished product.
And S7, performing surface polishing, grinding, cleaning and surface thinning treatment on the artificial stone semi-finished product obtained in the step S6 to obtain an artificial quartz stone plate finished product.
As a further improvement of the invention: the quartz chips have a particle size of 0.8 to 1.3 mm.
As a further improvement of the invention: the bottom or top layer of the sheet blank may be laid down at a thickness of one-fourth of the thickness of the desired sheet.
As a further improvement of the invention: the ratio of the casting thickness of the light layer prefabricated material to the casting thickness of the adjacent artificial board prefabricated material is 1: 1.5-2.
As a further improvement of the invention: before step S3, i.e., before the molding and curing process of the bottom-most artificial board preform, the bottom and the peripheral side walls of the mold cavity are coated with the surface antibacterial agent, and after step S5, the top layer of the board blank is coated with the surface antibacterial agent.
As a further improvement of the invention: the surface antibacterial agent is prepared from the following components in parts by weight: 0.2 part of nano titanium dioxide dispersion liquid, 5 parts of polyalcohol, 5 parts of acid anhydride and 5 parts of guanidine hydrochloride.
Compared with the prior art, the invention has the beneficial effects that:
1. according to the artificial quartz stone, the stone aggregate is added, so that the overall structural strength of the plate can be increased, the compressive strength and the bending resistance of the plate are obviously improved, and meanwhile, the artificial plate prefabricated material and the light layer prefabricated material are respectively mixed, so that the hollow glass microspheres and the stone aggregate are prevented from being in rigid collision in stirring, and the hollow glass microspheres are prevented from being damaged.
2. In the compounding process, carry out the compounding respectively through wood-based plate prefabricated material and light layer prefabricated material to can avoid mixing the in-process, light layer prefabricated material suspension is on the mixture upper strata and the inhomogeneous phenomenon of raw materials distribution that causes.
3. This artificial quartz stone, pour through light layer prefabricated material and the prefabricated material layering of wood-based plate and carry out steam cure many times and obtain the slabstone blank, and pass through high temperature high pressure solidification with the slabstone blank, thereby make and distribute evenly between each layer, the compatibility is strong, can not take place fault phenomenon when cutting the panel, and expect the range upon range of in turn at the wood-based plate that has the stone aggregate and the light layer that has cavity glass microballon, thereby make the slabstone finished product on the basis of guaranteeing higher compressive strength and bending strength, reduce panel bulk density, thereby reduce panel bulk weight, in order to show the weight advantage that improves panel.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example 1
In the embodiment of the invention, the lightweight artificial quartz stone is formed by an artificial board prefabricated material and a lightweight layer prefabricated material together.
The artificial board prefabricated material comprises the following components in parts by weight: 100-150 parts of white cement, 20-90 parts of silica powder, 300 parts of quartz dust, 50-100 parts of stone aggregate, 30-36 parts of water, 1.5-3 parts of water reducing agent, 70-80 parts of resin, 5-10 parts of color paste and 0.1-0.2 part of curing agent;
the light-weight layer prefabricated material comprises, by weight, 6-10 parts of hollow glass microspheres, 20-60 parts of silica powder and 30-70 parts of resin.
The processing technology of the artificial quartz stone comprises the following steps:
s1, preparing artificial board prefabricated material, taking 100 parts of white cement, 20 parts of silica powder, 200 parts of quartz chips, 50 parts of stone aggregate, 30 parts of water, 1.5 parts of water reducing agent, 70 parts of resin, 5 parts of color paste and 0.1 part of curing agent. Adding the raw materials into mixing equipment, and mixing at normal temperature for 30min to obtain prefabricated material for artificial board.
S2, preparing a lightweight layer prefabricated material, namely taking 6 parts of hollow glass microspheres, 20 parts of silica powder and 30 parts of resin as raw materials. Adding the raw materials into a mixing device, and mixing at normal temperature for 30min to obtain a light layer prefabricated material for later use.
In the processing technology of this implementation, owing to added the stone aggregate to can increase the overall structure intensity of panel, obviously improve panel compressive strength and bending resistance performance, simultaneously, carry out the compounding respectively with wood-based plate prefabricated material and lightweight layer prefabricated material, thereby can avoid cavity glass microballon and stone aggregate to take place rigid collision in the stirring, if mix above-mentioned raw materials together and stir, then can lead to cavity glass microballon and stone aggregate or quartz chip to carry out collision friction, lead to the cavity glass microballon to take place the damage. Furthermore, the phenomenon of uneven distribution of raw materials caused by suspension of the light-weight layer prefabricated material on the upper layer of the mixture in the mixing process can be avoided.
The quartz chips used in this example preferably have a particle size of 0.8 to 1.3 mm. If necessary, quartz chips can be used together with granite stone chips or general crushed stone chips to fill the gaps generated between the stone aggregates of larger size.
S3, preparing a mould frame by taking out a stone slab after the mould of the artificial board prefabricated material is solidified, spreading the artificial board prefabricated material prepared in the step S1 in the mould frame to form a bottom layer, wherein the spreading thickness of the bottom layer is preferably one fourth of the expected thickness of the board, carrying out vacuum vibration moulding on the transverse frame and the bottom layer spreading material, vacuumizing to separate out air in the bottom layer artificial board prefabricated material, and matching with vibration to realize the primary leveling of the surface of the bottom layer artificial board prefabricated material, wherein the vacuum degree is kept to be lower than 70 mmHg; and curing the bottom artificial board preform formed by vacuum vibration molding through high-temperature steam, wherein the curing is performed for about 1min under the vacuum degree of less than 50 mmHg.
S4, stacking and curing the light-weight layer prefabricated material, pouring the light-weight layer prefabricated material prepared in the step S2 on the upper layer of the prepared cured artificial board prefabricated material, paving the light-weight layer prefabricated material, and then performing vacuum vibration molding on the light-weight layer prefabricated material, wherein the vacuum degree is kept to be lower than 70mmHg so as to level the surface of the light-weight layer prefabricated material; solidifying the leveled artificial board prefabricated material and the light layer prefabricated material positioned on the upper layer of the leveled artificial board prefabricated material, wherein the solidification is carried out for about 1min under the vacuum degree lower than 50mmHg, and the ratio of the thickness of the light layer prefabricated material to the thickness of the adjacent artificial board prefabricated material is 1: 1.5-2.
And S5, repeating the steps S3 and S4, enabling the plate to form a layer alternating structure of artificial board prefabricated materials and light layer prefabricated materials, enabling the uppermost layer of the plate to be artificial board prefabricated materials, namely the uppermost layer and the lowermost layer of the plate blank to be artificial board prefabricated materials, and enabling the middle layer to be the artificial board prefabricated materials and the light layer prefabricated materials to be alternately stacked, and finally manufacturing the plate blank meeting the thickness requirement.
S6: and (2) curing the plate blank, namely, finishing final curing of the plate blank prepared in the step (S5) at high temperature and high pressure, wherein in the final curing process, white cement acts as a basic adhesive, so that the white cement and silica powder have a hardening reaction under the conditions of high temperature and high pressure steam, namely, curing is carried out in an autoclave for 5 to 10 hours at 7.0 to 10.0 bar and at 140 to 200 ℃, and a hydrothermal reaction is carried out between a layered light layer prefabricated material layer and an artificial stone prefabricated material layer so as to enable the hardening reaction to occur, so that the multilayer structures of the stone blank are compatible, condensed and cured into an integral structure, and a semi-finished product of the artificial stone plate is formed.
And S7, performing surface polishing, grinding, cleaning and surface thinning treatment on the artificial stone semi-finished product obtained in the step S6 to obtain an artificial quartz stone plate finished product.
The artificial quartz stone slab finished product manufactured by the steps is characterized in that steam curing and final high-temperature high-pressure sealing curing are carried out between the light layer prefabricated material inside the artificial quartz stone slab and the artificial board prefabricated material for many times, so that the layers are uniformly distributed, the compatibility is high, the fault phenomenon can not occur when the artificial quartz stone slab is cut, the artificial board with stone aggregate and the light layer prefabricated material with hollow glass beads are alternately stacked, and the whole density of the artificial quartz stone slab is reduced on the basis of ensuring higher compressive strength and bending strength of the finished product of the stone slab, so that the whole weight of the stone slab is reduced.
In this embodiment, before step S3, i.e., before the molding and curing process of the bottom-most artificial board preform, the surface antibacterial agent is coated on the bottom and the peripheral side walls of the mold forming cavity, and after step S5, the surface antibacterial agent is coated on the top layer of the board blank. The surface antibacterial agent is prepared from the following components in parts by weight: 0.2 part of nano titanium dioxide dispersion liquid, 5 parts of polyalcohol, 5 parts of acid anhydride and 5 parts of guanidine hydrochloride. And the surface of the plate blank is coated by coating the surface antibacterial agent so as to improve the antibacterial performance of the plate.
Example 2
In the embodiment of the invention, the lightweight artificial quartz stone is formed by an artificial board prefabricated material and a lightweight layer prefabricated material together.
The artificial board prefabricated material comprises the following components in parts by weight: 100-150 parts of white cement, 20-90 parts of silica powder, 300 parts of quartz dust, 50-100 parts of stone aggregate, 30-36 parts of water, 1.5-3 parts of water reducing agent, 70-80 parts of resin, 5-10 parts of color paste and 0.1-0.2 part of curing agent.
The light-weight layer prefabricated material comprises, by weight, 6-10 parts of hollow glass microspheres, 20-60 parts of silica powder and 30-70 parts of resin.
The processing technology of the artificial quartz stone comprises the following steps:
s1, preparing artificial board prefabricated material, taking 130 parts of white cement, 70 parts of silica powder, 250 parts of quartz chips, 80 parts of stone aggregate, 33 parts of water, 2 parts of water reducing agent, 75 parts of resin, 8 parts of color paste and 0.1 part of curing agent. Adding the raw materials into mixing equipment, and mixing at normal temperature for 30min to obtain prefabricated material for artificial board.
S2, preparing a lightweight layer prefabricated material, namely taking 8 parts of hollow glass microspheres, 40 parts of silica powder and 50 parts of resin as raw materials. Adding the raw materials into a mixing device, and mixing at normal temperature for 30min to obtain a light layer prefabricated material for later use.
S3, preparing a mould frame by taking out a stone slab after the mould of the artificial board prefabricated material is solidified, spreading the artificial board prefabricated material prepared in the step S1 in the mould frame to form a bottom layer, wherein the spreading thickness of the bottom layer is preferably one fourth of the expected thickness of the board, carrying out vacuum vibration moulding on the transverse frame and the bottom layer spreading material, vacuumizing to separate out air in the bottom layer artificial board prefabricated material, and matching with vibration to realize the primary leveling of the surface of the bottom layer artificial board prefabricated material, wherein the vacuum degree is kept to be lower than 70 mmHg; and curing the bottom artificial board preform formed by vacuum vibration molding through high-temperature steam, wherein the curing is performed for about 1min under the vacuum degree of less than 50 mmHg.
S4, stacking and curing the light-weight layer prefabricated material, pouring the light-weight layer prefabricated material prepared in the step S2 on the upper layer of the prepared cured artificial board prefabricated material, paving the light-weight layer prefabricated material, and then performing vacuum vibration molding on the light-weight layer prefabricated material, wherein the vacuum degree is kept to be lower than 70mmHg so as to level the surface of the light-weight layer prefabricated material; solidifying the leveled artificial board prefabricated material and the light layer prefabricated material positioned on the upper layer of the leveled artificial board prefabricated material, wherein the solidification is carried out for about 1min under the vacuum degree lower than 50mmHg, and the ratio of the thickness of the light layer prefabricated material to the thickness of the adjacent artificial board prefabricated material is 1: 1.5-2.
And S5, repeating the steps S3 and S4, enabling the plate to form a layer alternating structure of artificial board prefabricated materials and light layer prefabricated materials, enabling the uppermost layer of the plate to be artificial board prefabricated materials, namely the uppermost layer and the lowermost layer of the plate blank to be artificial board prefabricated materials, and enabling the middle layer to be the artificial board prefabricated materials and the light layer prefabricated materials to be alternately stacked, and finally manufacturing the plate blank meeting the thickness requirement.
S6: and (2) curing the plate blank, namely, finishing final curing of the plate blank prepared in the step (S5) at high temperature and high pressure, wherein in the final curing process, white cement acts as a basic adhesive, so that the white cement and silica powder have a hardening reaction under the conditions of high temperature and high pressure steam, namely, curing is carried out in an autoclave for 5 to 10 hours at 7.0 to 10.0 bar and at 140 to 200 ℃, and a hydrothermal reaction is carried out between a layered light layer prefabricated material layer and an artificial stone prefabricated material layer so as to enable the hardening reaction to occur, so that the multilayer structures of the stone blank are compatible, condensed and cured into an integral structure, and a semi-finished product of the artificial stone plate is formed.
And S7, performing surface polishing, grinding, cleaning and surface thinning treatment on the artificial stone semi-finished product obtained in the step S6 to obtain an artificial quartz stone plate finished product.
Example 3
In the embodiment of the invention, the lightweight artificial quartz stone is formed by an artificial board prefabricated material and a lightweight layer prefabricated material together.
The artificial board prefabricated material comprises the following components in parts by weight: 100-150 parts of white cement, 20-90 parts of silica powder, 300 parts of quartz dust, 50-100 parts of stone aggregate, 30-36 parts of water, 1.5-3 parts of water reducing agent, 70-80 parts of resin, 5-10 parts of color paste and 0.1-0.2 part of curing agent.
The light-weight layer prefabricated material comprises, by weight, 6-10 parts of hollow glass microspheres, 20-60 parts of silica powder and 30-70 parts of resin.
The processing technology of the artificial quartz stone comprises the following steps:
s1, preparing artificial board prefabricated material, taking 150 parts of white cement, 90 parts of silica powder, 300 parts of quartz chips, 100 parts of stone aggregate, 36 parts of water, 3 parts of water reducing agent, 80 parts of resin, 10 parts of color paste and 0.2 part of curing agent. Adding the raw materials into mixing equipment, and mixing at normal temperature for 30min to obtain prefabricated material for artificial board.
S2, preparing a lightweight layer prefabricated material, namely taking 10 parts of hollow glass microspheres, 60 parts of silica powder and 70 parts of resin as raw materials. Adding the raw materials into a mixing device, and mixing at normal temperature for 30min to obtain a light layer prefabricated material for later use.
S3, preparing a mould frame by taking out a stone slab after the mould of the artificial board prefabricated material is solidified, spreading the artificial board prefabricated material prepared in the step S1 in the mould frame to form a bottom layer, wherein the spreading thickness of the bottom layer is preferably one fourth of the expected thickness of the board, carrying out vacuum vibration moulding on the transverse frame and the bottom layer spreading material, vacuumizing to separate out air in the bottom layer artificial board prefabricated material, and matching with vibration to realize the primary leveling of the surface of the bottom layer artificial board prefabricated material, wherein the vacuum degree is kept to be lower than 70 mmHg; and curing the bottom artificial board preform formed by vacuum vibration molding through high-temperature steam, wherein the curing is performed for about 1min under the vacuum degree of less than 50 mmHg.
S4, stacking and curing the light-weight layer prefabricated material, pouring the light-weight layer prefabricated material prepared in the step S2 on the upper layer of the prepared cured artificial board prefabricated material, paving the light-weight layer prefabricated material, and then performing vacuum vibration molding on the light-weight layer prefabricated material, wherein the vacuum degree is kept to be lower than 70mmHg so as to level the surface of the light-weight layer prefabricated material; solidifying the leveled artificial board prefabricated material and the light layer prefabricated material positioned on the upper layer of the leveled artificial board prefabricated material, wherein the solidification is carried out for about 1min under the vacuum degree lower than 50mmHg, and the ratio of the thickness of the light layer prefabricated material to the thickness of the adjacent artificial board prefabricated material is 1: 1.5-2.
And S5, repeating the steps S3 and S4, enabling the plate to form a layer alternating structure of artificial board prefabricated materials and light layer prefabricated materials, enabling the uppermost layer of the plate to be artificial board prefabricated materials, namely the uppermost layer and the lowermost layer of the plate blank to be artificial board prefabricated materials, and enabling the middle layer to be the artificial board prefabricated materials and the light layer prefabricated materials to be alternately stacked, and finally manufacturing the plate blank meeting the thickness requirement.
S6: and (2) curing the plate blank, namely, finishing final curing of the plate blank prepared in the step (S5) at high temperature and high pressure, wherein in the final curing process, white cement acts as a basic adhesive, so that the white cement and silica powder have a hardening reaction under the conditions of high temperature and high pressure steam, namely, curing is carried out in an autoclave for 5 to 10 hours at 7.0 to 10.0 bar and at 140 to 200 ℃, and a hydrothermal reaction is carried out between a layered light layer prefabricated material layer and an artificial stone prefabricated material layer so as to enable the hardening reaction to occur, so that the multilayer structures of the stone blank are compatible, condensed and cured into an integral structure, and a semi-finished product of the artificial stone plate is formed.
And S7, performing surface polishing, grinding, cleaning and surface thinning treatment on the artificial stone semi-finished product obtained in the step S6 to obtain an artificial quartz stone plate finished product.
Comparative example:
the comparative example is prepared by adopting a light raw material blending process in the prior art, namely blending the light raw material and the common raw material together and adopting single curing, and specifically, the light artificial quartz stone in the comparative example comprises the following components in parts by weight: 100-150 parts of white cement, 20-90 parts of silica powder, 300 parts of quartz dust, 30-36 parts of water, 1.5-3 parts of water reducing agent, 70-80 parts of resin, 5-10 parts of color paste, 0.1-0.2 part of curing agent and 6-10 parts of hollow glass microspheres.
And putting the components of the formula into a mixing device to mix for at least 30min, pouring the mixed prefabricated material into a mold frame to perform vibration leveling, performing vacuum pressing, performing high-temperature high-pressure curing on the pressed plate material, and performing later surface treatment to obtain the composite material.
The parameter detection and evaluation of the embodiment of the invention and the comparative example are as follows:
TABLE 1
As can be seen from table 1, the bending strength, the compressive strength, the impact strength and the bulk density of the artificial quartz stone slab of the embodiment of the present invention all meet the detection standards, and the bending strength, the compressive strength and the impact strength are all significantly improved compared to the comparative example, it is noted that the increase value of the bulk density of the artificial quartz stone slab of the embodiment of the present invention relative to the bulk density of the comparative example is not large, i.e., the increase value of the bulk density is between 0.1 g/cm and 0.6g/cm, but the other three detection parameters are significantly improved, which means that the artificial quartz stone slab of the present invention has significant quality advantages and uniform component distribution, and further significantly improves the slab performance without any change in quality. Although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that various changes in the embodiments and/or modifications of the invention can be made, and equivalents and modifications of some features of the invention can be made without departing from the spirit and scope of the invention.
Claims (7)
1. A lightweight artificial quartz stone is characterized in that: the method comprises the following steps of forming an artificial board prefabricated material and a light layer prefabricated material together;
the artificial board prefabricated material comprises the following components in parts by weight: 100-150 parts of white cement, 20-90 parts of silica powder, 300 parts of quartz dust, 50-100 parts of stone aggregate, 30-36 parts of water, 1.5-3 parts of water reducing agent, 70-80 parts of resin, 5-10 parts of color paste and 0.1-0.2 part of curing agent;
the light layer prefabricated material comprises the following components in parts by weight: 6-10 parts of hollow glass microspheres, 20-60 parts of silica powder and 30-70 parts of resin.
2. A processing technology of artificial quartz stone comprises the following steps:
s1, preparing a prefabricated material of the artificial board, namely taking 100 parts of white cement, 20-90 parts of silica powder, 200 parts of quartz chips, 50-100 parts of stone aggregate, 30-36 parts of water, 1.5-3 parts of a water reducing agent, 70-80 parts of resin, 5-10 parts of color paste and 0.1-0.2 part of a curing agent as raw materials; adding the raw materials into mixing equipment, and mixing at normal temperature to obtain an artificial board prefabricated material for later use;
s2, preparing a light-weight layer prefabricated material, namely adding 6-10 parts of hollow glass microspheres, 20-60 parts of silica powder and 30-70 parts of resin into mixing equipment, and mixing at normal temperature to prepare the light-weight layer prefabricated material for later use;
s3, performing molding and curing on the artificial board prefabricated material, taking out the stone slab to prepare a mold frame, laying the artificial board prefabricated material prepared in the step S1 in the mold frame and forming a bottom layer, performing vacuum vibration molding on the transverse frame and the bottom layer laid material, vacuumizing to separate out air in the bottom layer artificial board prefabricated material, and matching vibration to realize primary surface leveling, wherein the vacuum degree is kept to be lower than 70 mmHg; curing the bottom artificial board prefabricated material formed by vacuum vibration molding through high-temperature steam, wherein the curing is carried out for 1min under the vacuum degree lower than 50 mmHg;
s4, stacking and molding the light-weight layer prefabricated material, pouring the light-weight layer prefabricated material prepared in the step S2 on the upper layer of the prepared solidified artificial board prefabricated material, paving the light-weight layer prefabricated material, and performing vacuum vibration molding on the light-weight layer prefabricated material to level the surface of the light-weight layer prefabricated material; solidifying the leveled artificial board prefabricated material and the prefabricated material of the light layer positioned on the upper layer of the leveled artificial board prefabricated material;
s5, repeating the steps S3 and S4, enabling the plate to form a layer alternating structure of artificial board prefabricated materials and light layer prefabricated materials, enabling the uppermost layer of the plate to be artificial board prefabricated materials, namely the uppermost layer and the lowermost layer of the plate blank to be artificial board prefabricated materials, and enabling the middle layer to be artificial board prefabricated materials and light layer prefabricated materials which are alternately stacked, and finally manufacturing the plate blank meeting the thickness requirement;
s6: curing the plate blank, namely, finishing final curing of the plate blank prepared in the step S5 through high temperature and high pressure, and curing for 5 to 10 hours in an autoclave at 7.0 to 10.0 bar and at the temperature of between 140 and 200 ℃ to form an artificial stone plate semi-finished product;
and S7, performing surface polishing, grinding, cleaning and surface thinning treatment on the artificial stone semi-finished product obtained in the step S6 to obtain an artificial quartz stone plate finished product.
3. A lightweight artificial quartz stone and a process for producing the same according to claim 2, wherein: the quartz chips have a particle size of 0.8 to 1.3 mm.
4. A lightweight artificial quartz stone and a process for producing the same according to claim 2, wherein: the bottom or top layer of the sheet blank may be laid down at a thickness of one-fourth of the thickness of the desired sheet.
5. A lightweight artificial quartz stone and a process for producing the same according to claim 2, wherein: the ratio of the casting thickness of the light layer prefabricated material to the casting thickness of the adjacent artificial board prefabricated material is 1: 1.5-2.
6. A lightweight artificial quartz stone and a process for producing the same according to claim 2, wherein: before step S3, i.e., before the molding and curing process of the bottom-most artificial board preform, the bottom and the peripheral side walls of the mold cavity are coated with the surface antibacterial agent, and after step S5, the top layer of the board blank is coated with the surface antibacterial agent.
7. A lightweight artificial quartz stone and a process for producing the same according to claim 6, wherein: the surface antibacterial agent is prepared from the following components in parts by weight: 0.2 part of nano titanium dioxide dispersion liquid, 5 parts of polyalcohol, 5 parts of acid anhydride and 5 parts of guanidine hydrochloride.
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