An environmentally friendly spraying process for preparing artificial quartz stone

Abstract

An environmentally friendly spray coating process for artificial quartz stone includes the following steps: Step 1, preparing raw materials according to the composition of artificial quartz stone, then mixing, crushing and stirring the raw materials evenly to obtain a premix; Step 2, preparing an environmentally friendly color paste, then spraying the environmentally friendly color paste onto the premix, so that a layer of color paste adheres to the surface of the premix; Step 3, injecting the premix obtained in Step 2 into a mold, vibrating and pressing, curing, and demolding to obtain a semi-finished product; Step 4, fixing the thickness of the semi-finished product, then polishing it in a polishing machine, and then inspecting and cutting it into the required size to obtain artificial quartz stone; The environmentally friendly color paste is composed of the following raw materials: water-based polyurethane resin, mineral pigments, mica powder, organic bentonite, dodecyl alcohol ester, silica fume, nano-magnesium hydroxide powder, and attapulgite. This invention reduces environmental pollution by limiting the raw material composition of the environmentally friendly color paste and replacing chemical pigments with mineral pigments.

Description

Technical Field

[0001] This invention belongs to the field of artificial quartz stone preparation, specifically relating to an environmentally friendly spraying process for preparing artificial quartz stone. Background Technology

[0002] Currently, the stone market is broadly divided into two categories: natural stone and artificial stone. Natural stone includes granite and marble, while artificial stone includes engineered stone, quartz stone, and microcrystalline stone. Quartz stone is a new type of polymer material made from a mixture of natural quartz (granules and fine powder), resin, and pigments. Quartz stone boasts a wide variety of colors and patterns, excellent decorative effects, high hardness, good wear resistance, strong stain resistance, corrosion resistance, environmental friendliness, no radiation, high temperature resistance without deformation, high strength, good toughness, and easy bonding. Compared to natural stone, quartz stone has unique advantages such as being non-toxic, pollution-free, and available in a rich array of colors; compared to engineered stone, quartz stone has advantages such as high toughness and high temperature resistance. Because of its unparalleled advantages and characteristics compared to natural stone and engineered stone, quartz stone has become a new favorite in the stone market and is widely used in the construction industry.

[0003] Artificial quartz stone uses primarily chemical pigments, which have insufficient adhesion to natural quartz, easily leading to uneven color distribution and affecting the color and appearance of the artificial quartz stone. Furthermore, the chemical pigments used also pose a certain degree of pollution and impact the environment, requiring further improvement. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide an environmentally friendly spraying process for preparing artificial quartz stone.

[0005] The present invention adopts the following technical solutions:

[0006] A process for preparing environmentally friendly sprayed artificial quartz stone includes the following steps:

[0007] Step 1: Prepare the raw materials according to the composition of artificial quartz stone, and then mix, crush and stir the raw materials evenly to obtain a premix.

[0008] Step 2: Prepare environmentally friendly color paste, and then spray the environmentally friendly color paste onto the premix to coat the surface of the premix with a layer of color paste.

[0009] Step 3: Inject the premixed material obtained in Step 2 into the mold, vibrate and press, solidify, and demold to obtain a semi-finished product;

[0010] Step four: Determine the thickness of the semi-finished product, then polish it in a polishing machine, and finally inspect and cut it into the required size to obtain artificial quartz stone;

[0011] The environmentally friendly color paste is composed of the following raw materials in parts by weight: 100 parts water-based polyurethane resin, 20-30 parts mineral pigment, 3-5 parts mica powder, 1-2 parts organic bentonite, 1-2 parts dodecyl alcohol ester, 4-8 parts silica fume, 2-3 parts nano magnesia mineral powder, and 10-15 parts attapulgite.

[0012] Furthermore, the mineral pigment includes one or more of hematite, limonite, realgar, chalcopyrite, azurite, cinnabar, and talc.

[0013] Furthermore, the artificial quartz stone is composed of the following raw materials in parts by weight: 40-50 parts quartz stone, 20-30 parts construction waste, 15-18 parts carbon fiber scrap, 35-50 parts resin, 3-5 parts dispersant, 8-12 parts curing agent, 6-9 parts silica fume, 3-5 parts brucite powder, and 8-12 parts asbestos fiber.

[0014] Furthermore, the construction waste is composed of the following parts by weight of raw materials: 15-25 parts of 5-10mm construction waste, 35-50 parts of 3-5mm construction waste, and 10-20 parts of 1-2mm construction waste.

[0015] Furthermore, the quartz sand is composed of the following parts by weight of raw materials: 10-20 parts of 4-7 mm quartz sand, 20-30 parts of 0.5-1 mm quartz sand, and 10-20 parts of 2-4 mm quartz sand.

[0016] Furthermore, the preparation method of the environmentally friendly color paste is as follows: mineral pigments, silica fume and half of the dodecyl alcohol ester are added sequentially to waterborne polyurethane resin, the stirring speed is controlled at 250 r / min, and the mixture is stirred for 25 min. Then, organic bentonite, mica powder and the other half of the dodecyl alcohol ester are added sequentially, the stirring speed is controlled at 3350 r / min, and the mixture is stirred for 60 min to obtain the environmentally friendly color paste.

[0017] Furthermore, in step two, a plunger pump is used to spray the environmentally friendly pigment onto the premix. The pressure of the plunger pump is 20-25 MPa, and the spraying speed is 2 kgs / min.

[0018] Furthermore, in step four, during the polishing process, the gloss level is polished to 40-70°.

[0019] As can be seen from the above description of the present invention, compared with the prior art, the beneficial effects of the present invention are as follows: The present invention reduces environmental pollution by limiting the raw material composition of the environmentally friendly color paste, replacing chemical pigments with mineral pigments, and adding mica powder and dodecyl alcohol ester to improve the adhesion of the color paste to the premix, so that the mineral pigments are stably attached to the premix, ensuring the color development of the final artificial quartz stone; and by adding silica fume and nano-magnesium hydroxide mineral powder in combination with other raw materials, the shrinkage rate of the environmentally friendly color paste after film formation can be reduced, preventing the color paste formed on the premix from cracking, so as to ensure that the color paste is uniformly attached to the premix.

[0020] Specifically, the raw material composition of artificial quartz stone is limited, with construction waste replacing part of the quartz sand. This reduces the amount of quartz sand used, lowering production costs, while simultaneously enabling the recycling of construction waste, reducing its land occupation and processing costs. The particle size distribution of the quartz stone and construction waste is also limited, and carbon fiber scraps and asbestos fibers are used as fillers to ensure the strength of the prepared quartz stone. Furthermore, silica fume, magnesia powder, resin, and curing agent are added to lower the resin curing temperature, allowing for room-temperature curing and reducing the shrinkage rate of the artificial quartz stone during curing. This also eliminates internal stress during curing, preventing cracking and improving the yield rate.

[0021] The artificial quartz stone prepared by this invention has a smooth, glossy, and crack-free surface, as well as high hardness and sufficient strength, meeting the requirements for use. The environmentally friendly color paste and the raw materials used in the artificial quartz stone are all conventional. Through the mutual cooperation between the raw materials and specific preparation processes, the specified artificial quartz stone is obtained. Furthermore, it realizes the recycling of construction waste and carbon fiber scraps, reducing resource waste and conforming to the concept of sustainable development. Detailed Implementation

[0022] The present invention will be further described below through specific embodiments.

[0023] A process for preparing environmentally friendly sprayed artificial quartz stone includes the following steps:

[0024] Step 1: Prepare the raw materials according to the composition of artificial quartz stone, and then mix, crush and stir the raw materials evenly to obtain a premix.

[0025] Step 2: Prepare environmentally friendly color paste, and then spray the environmentally friendly color paste onto the premix to coat the surface of the premix with a layer of color paste. A plunger pump is used to spray the environmentally friendly color paste onto the premix. The pressure of the plunger pump is 20-25 MPa, and the spraying speed is 2 kgs / min.

[0026] Step 3: Inject the premixed material obtained in Step 2 into the mold, vibrate and press, solidify, and demold to obtain a semi-finished product;

[0027] Step four: Determine the thickness of the semi-finished product, then polish it in a polishing machine until the gloss reaches 40-70°. Next, inspect and cut it into the required size to obtain artificial quartz stone.

[0028] Artificial quartz stone is composed of the following raw materials in parts by weight: quartz stone 40-50 parts, construction waste 20-30 parts, carbon fiber scraps 15-18 parts, resin 35-50 parts, dispersant 3-5 parts, curing agent 8-12 parts, silica fume 6-9 parts, magnesia mineral powder 3-5 parts, and asbestos fiber 8-12 parts.

[0029] Specifically, the construction waste is composed of the following parts by weight of raw materials: 15-25 parts of 5-10mm construction waste, 35-50 parts of 3-5mm construction waste, and 10-20 parts of 1-2mm construction waste; the quartz sand is composed of the following parts by weight of raw materials: 10-20 parts of 4-7mm quartz sand, 20-30 parts of 0.5-1mm quartz sand, and 10-20 parts of 2-4mm quartz sand.

[0030] The environmentally friendly color paste is composed of the following raw materials in parts by weight: 100 parts water-based polyurethane resin, 20-30 parts mineral pigments, 3-5 parts mica powder, 1-2 parts organic bentonite, 1-2 parts dodecyl alcohol ester, 4-8 parts silica fume, 2-3 parts nano brucite mineral powder, and 10-15 parts attapulgite. Specifically, the mineral pigments include one or more of hematite, limonite, realgar, chalcopyrite, azurite, cinnabar, and talc.

[0031] The specific preparation method is as follows: mineral pigments, silica fume and half of the dodecyl alcohol ester are added sequentially to waterborne polyurethane resin, the rotation speed is controlled at 250 r / min, and the mixture is stirred for 25 min. Then, organic bentonite, mica powder and the other half of the dodecyl alcohol ester are added sequentially, the rotation speed is controlled at 3350 r / min, and the mixture is stirred for 60 min to obtain the environmentally friendly color paste.

[0032] Example 1

[0033] A process for preparing environmentally friendly sprayed artificial quartz stone includes the following steps:

[0034] Step 1: Prepare the raw materials according to the composition of artificial quartz stone, and then mix, crush and stir the raw materials evenly to obtain a premix.

[0035] Step 2: Prepare environmentally friendly color paste, and then spray the environmentally friendly color paste onto the premix to coat the surface of the premix with a layer of color paste. A plunger pump is used to spray the environmentally friendly color paste onto the premix. The pressure of the plunger pump is 20 MPa and the spraying speed is 2 kgs / min.

[0036] Step 3: Inject the premixed material obtained in Step 2 into the mold, vibrate and press, solidify, and demold to obtain a semi-finished product;

[0037] Step four: Determine the thickness of the semi-finished product, then polish it in a polishing machine until the gloss reaches 40-70°. Next, inspect and cut it into the required size to obtain artificial quartz stone.

[0038] The artificial quartz stone is composed of the following raw materials in parts by weight: 40 parts quartz stone, 30 parts construction waste, 15 parts carbon fiber scraps, 35 parts resin, 5 parts dispersant, 8 parts curing agent, 6 parts silica fume, 5 parts magnesia mineral powder, and 12 parts asbestos fiber.

[0039] Specifically, the construction waste is composed of the following parts by weight of raw materials: 15 parts of 5-10mm construction waste, 50 parts of 3-5mm construction waste, and 10 parts of 1-2mm construction waste; the quartz sand is composed of the following parts by weight of raw materials: 10 parts of 4-7mm quartz sand, 30 parts of 0.5-1mm quartz sand, and 10 parts of 2-4mm quartz sand.

[0040] The environmentally friendly color paste is composed of the following raw materials in parts by weight: 100 parts water-based polyurethane resin, 20 parts mineral pigment, 5 parts mica powder, 1 part organic bentonite, 2 parts dodecyl alcohol ester, 4 parts silica fume, 3 parts nano magnesia mineral powder, and 10 parts attapulgite.

[0041] The specific preparation method is as follows: mineral pigments, silica fume and half of the dodecyl alcohol ester are added sequentially to waterborne polyurethane resin, the rotation speed is controlled at 250 r / min, and the mixture is stirred for 25 min. Then, organic bentonite, mica powder and the other half of the dodecyl alcohol ester are added sequentially, the rotation speed is controlled at 3350 r / min, and the mixture is stirred for 60 min to obtain the environmentally friendly color paste.

[0042] Example 2

[0043] A process for preparing environmentally friendly sprayed artificial quartz stone includes the following steps:

[0044] Step 1: Prepare the raw materials according to the composition of artificial quartz stone, and then mix, crush and stir the raw materials evenly to obtain a premix.

[0045] Step 2: Prepare environmentally friendly color paste, and then spray the environmentally friendly color paste onto the premix to coat the surface of the premix with a layer of color paste. A plunger pump is used to spray the environmentally friendly color paste onto the premix. The pressure of the plunger pump is 25 MPa and the spraying speed is 2 kgs / min.

[0046] Step 3: Inject the premixed material obtained in Step 2 into the mold, vibrate and press, solidify, and demold to obtain a semi-finished product;

[0047] Step four: Determine the thickness of the semi-finished product, then polish it in a polishing machine until the gloss reaches 40-70°. Next, inspect and cut it into the required size to obtain artificial quartz stone.

[0048] Artificial quartz stone is composed of the following raw materials in parts by weight: 50 parts quartz stone, 20 parts construction waste, 18 parts carbon fiber scraps, 50 parts resin, 3 parts dispersant, 12 parts curing agent, 9 parts silica fume, 3 parts brucite powder, and 8 parts asbestos fiber.

[0049] Specifically, the construction waste is composed of the following parts by weight of raw materials: 25 parts of 5-10mm construction waste, 35 parts of 3-5mm construction waste, and 20 parts of 1-2mm construction waste; the quartz sand is composed of the following parts by weight of raw materials: 20 parts of 4-7mm quartz sand, 20 parts of 0.5-1mm quartz sand, and 20 parts of 2-4mm quartz sand.

[0050] The environmentally friendly color paste is composed of the following raw materials in parts by weight: 100 parts water-based polyurethane resin, 30 parts mineral pigment, 3 parts mica powder, 2 parts organic bentonite, 1 part dodecyl alcohol ester, 8 parts silica fume, 2 parts nano magnesia mineral powder, and 15 parts attapulgite.

[0051] The specific preparation method is as follows: mineral pigments, silica fume and half of the dodecyl alcohol ester are added sequentially to waterborne polyurethane resin, the rotation speed is controlled at 250 r / min, and the mixture is stirred for 25 min. Then, organic bentonite, mica powder and the other half of the dodecyl alcohol ester are added sequentially, the rotation speed is controlled at 3350 r / min, and the mixture is stirred for 60 min to obtain the environmentally friendly color paste.

[0052] Example 3

[0053] A process for preparing environmentally friendly sprayed artificial quartz stone includes the following steps:

[0054] Step 1: Prepare the raw materials according to the composition of artificial quartz stone, and then mix, crush and stir the raw materials evenly to obtain a premix.

[0055] Step 2: Prepare environmentally friendly color paste, and then spray the environmentally friendly color paste onto the premix to coat the surface of the premix with a layer of color paste. A plunger pump is used to spray the environmentally friendly color paste onto the premix. The pressure of the plunger pump is 22 MPa and the spraying speed is 2 kgs / min.

[0056] Step 3: Inject the premixed material obtained in Step 2 into the mold, vibrate and press, solidify, and demold to obtain a semi-finished product;

[0057] Step four: Determine the thickness of the semi-finished product, then polish it in a polishing machine until the gloss reaches 40-70°. Next, inspect and cut it into the required size to obtain artificial quartz stone.

[0058] Artificial quartz stone is composed of the following raw materials in parts by weight: 45 parts quartz stone, 25 parts construction waste, 16 parts carbon fiber scraps, 42 parts resin, 4 parts dispersant, 10 parts curing agent, 8 parts silica fume, 4 parts brucite powder, and 10 parts asbestos fiber.

[0059] Specifically, the construction waste is composed of the following parts by weight of raw materials: 20 parts of 5-10mm construction waste, 42 parts of 3-5mm construction waste, and 15 parts of 1-2mm construction waste; the quartz sand is composed of the following parts by weight of raw materials: 15 parts of 4-7mm quartz sand, 25 parts of 0.5-1mm quartz sand, and 15 parts of 2-4mm quartz sand.

[0060] The environmentally friendly color paste is composed of the following raw materials in parts by weight: 100 parts water-based polyurethane resin, 25 parts mineral pigment, 4 parts mica powder, 1.5 parts organic bentonite, 1.5 parts dodecyl alcohol ester, 6 parts silica fume, 2.5 parts nano magnesia mineral powder, and 12 parts attapulgite.

[0061] The specific preparation method is as follows: mineral pigments, silica fume and half of the dodecyl alcohol ester are added sequentially to waterborne polyurethane resin, the rotation speed is controlled at 250 r / min, and the mixture is stirred for 25 min. Then, organic bentonite, mica powder and the other half of the dodecyl alcohol ester are added sequentially, the rotation speed is controlled at 3350 r / min, and the mixture is stirred for 60 min to obtain the environmentally friendly color paste.

[0062] The artificial quartz stones prepared in Examples 1 to 3 were compared with commercially available conventional artificial quartz stones, and the following data were obtained:

[0063] Table 1 Test Data for Each Embodiment

[0064] project Flexural strength (MPa) Compressive strength (MPa) Drop ball impact (N) Mohs hardness Example 1 78.6 248.2 49.3 7.5 Example 2 79.2 248.5 49.8 7.6 Example 3 80.5 248.3 50.4 7.6 Comparative Example 52.5 200.6 39.6 6

[0065] As shown in the table above, the artificial quartz stone prepared by this invention has high hardness and sufficient strength, meeting the application requirements. Specifically, the raw material composition of the artificial quartz stone is limited, with construction waste replacing part of the quartz sand. This reduces the amount of quartz sand used, lowering the preparation cost, while simultaneously achieving the recycling of construction waste, reducing the space occupied and processing costs of construction waste. The particle size composition of the quartz stone and construction waste is also limited, and carbon fiber scraps and asbestos fibers are used as fillers to ensure the strength of the prepared quartz stone. Furthermore, silica fume, magnesia powder, resin, and curing agent are added to lower the resin curing temperature, allowing for room temperature curing and molding. This also reduces the shrinkage rate of the artificial quartz stone during curing, eliminates internal stress during curing, prevents cracking, and improves the yield.

[0066] In summary, the artificial quartz stone prepared by this invention has a smooth, glossy, and crack-free surface, as well as high hardness and sufficient strength, meeting usage requirements. The environmentally friendly colorant and the raw materials used in the artificial quartz stone are all conventional. Through the synergistic effect of these raw materials and a specific preparation process, a defined artificial quartz stone is obtained. Furthermore, this invention enables the recycling of construction waste and carbon fiber scraps, reducing resource waste and aligning with the concept of sustainable development.

[0067] The above description is merely a preferred embodiment of the present invention and should not be construed as limiting the scope of the present invention. All equivalent changes and modifications made in accordance with the scope of the patent application and the contents of the specification of the present invention should still fall within the scope of the patent of the present invention.

Claims

1. A process for preparing environmentally friendly sprayed artificial quartz stone, characterized in that: Includes the following steps: Step 1: Prepare the raw materials according to the composition of artificial quartz stone, and then mix, crush and stir the raw materials evenly to obtain a premix. Step 2: Prepare environmentally friendly color paste, and then spray the environmentally friendly color paste onto the premix to coat the surface of the premix with a layer of color paste. Step 3: Inject the premixed material obtained in Step 2 into the mold, vibrate and press, solidify, and demold to obtain a semi-finished product; Step four: Determine the thickness of the semi-finished product, then polish it in a polishing machine, and finally inspect and cut it into the required size to obtain artificial quartz stone; The environmentally friendly color paste is composed of the following raw materials in parts by weight: 100 parts water-based polyurethane resin, 20-30 parts mineral pigment, 3-5 parts mica powder, 1-2 parts organic bentonite, 1-2 parts dodecyl alcohol ester, 4-8 parts silica fume, 2-3 parts nano magnesia mineral powder, and 10-15 parts attapulgite. The artificial quartz stone is composed of the following raw materials in parts by weight: 40-50 parts quartz stone, 20-30 parts construction waste, 15-18 parts carbon fiber scrap, 35-50 parts resin, 3-5 parts dispersant, 8-12 parts curing agent, 6-9 parts silica fume, 3-5 parts magnesia mineral powder, and 8-12 parts asbestos fiber.

2. The process for preparing environmentally friendly sprayed artificial quartz stone according to claim 1, characterized in that: The mineral pigments include one or more of hematite, limonite, realgar, chalcopyrite, azurite, cinnabar, and talc.

3. The process for preparing environmentally friendly sprayed artificial quartz stone according to claim 1, characterized in that: The preparation method of the environmentally friendly color paste is as follows: mineral pigments, silica fume and half of the dodecyl alcohol ester are added sequentially to waterborne polyurethane resin, the stirring speed is controlled at 250 r / min, and the mixture is stirred for 25 min. Then, organic bentonite, mica powder and the other half of the dodecyl alcohol ester are added sequentially, the stirring speed is controlled at 3350 r / min, and the mixture is stirred for 60 min to obtain the environmentally friendly color paste.

4. The process for preparing environmentally friendly sprayed artificial quartz stone according to claim 1, characterized in that: In step two, a plunger pump is used to spray the environmentally friendly pigment onto the premix. The pressure of the plunger pump is 20-25 MPa, and the spraying speed is 2 kgs / min.

5. The process for preparing environmentally friendly sprayed artificial quartz stone according to claim 1, characterized in that: In step four, during the polishing process, polish until the gloss level reaches 40-70°.