Assembled rock slab and preparation method thereof

Abstract

The present invention discloses an assembled rock slab and a preparation method thereof, the preparation method comprising the following steps: (1) sandblasting the back of the rock slab; (2) applying an adhesive to the back of the sandblasted rock slab; (3) laminating the rock slab with the adhesive-coated side to a substrate, and then preliminarily bonding the rock slab and the substrate by local top pressing; (4) statically pressing the preliminarily bonded rock slab and the substrate to obtain a prefabricated product; (5) processing the prefabricated product to obtain an assembled rock slab finished product. Implementation of the present invention can enable the rock slab to be effectively bonded to a variety of different substrates, with good bonding performance and ideal flame retardant effect, making the rock slab easy to process and increasing the application range of the rock slab.

Description

Technical Field

[0001] The present invention relates to the technical field of rock slab processing, and in particular to an assembled rock slab and a preparation method thereof. Background Art

[0002] Slate is a sintered dense stone. Its primary components are clay, feldspar powder, and silica. It is pressed using presses exceeding 10,000 tons and fired in high-temperature kilns. The unique manufacturing process of slate restores the stone's texture and color, creating a unique aesthetic. Furthermore, slate possesses excellent physical and chemical properties.

[0003] At present, rock slabs are favored by the majority of consumers, and rock slabs are also facing a favorable opportunity for development. This is a product born in line with the times and is also another track for the development of ceramic products. With the popularization of the application of rock slabs, the following shortcomings are also exposed in actual application: the traditional wet paving method, due to the large size of the rock slabs, needs to be fixed for a certain period of time during paving to ensure the final effect of paving. If the fixing time is not enough or the method is wrong, it is easy to shift, resulting in rework; secondly, the decoration relies too much on the craftsmanship of cement workers, the labor cost of decoration is high, and the construction period is long. Thirdly, the secondary decoration will generate a lot of construction waste and dust, polluting the environment and not environmentally friendly.

[0004] However, rock slabs themselves present challenges such as difficulty in processing, easy breakage during processing, and safety issues. To address these issues, those skilled in the art have proposed rock slab composite panels. However, existing rock slab composite panels have limited application, typically using different composite materials for different substrates, bonded to the rock slab to form an integrated structure.

[0005] Prior Art 1 is a Chinese patent document with publication number CN113650376A, which discloses a lightweight integrated rock board and its preparation method. The lightweight integrated rock board comprises, from bottom to top, a multilayer board, an adhesive layer, and a rock board. The lightweight integrated rock board of this invention, by combining the rock board with the multilayer board, not only greatly improves the bending strength of the lightweight integrated rock board, but also solves the problem of 3mm rock boards being easily broken during transportation or laying. However, this prior art only solves the problem of poor bending strength, but does not address the technical problems of good bonding performance of the rock board composite board and ideal flame retardant effect.

[0006] Prior art 2 is a Chinese patent document with publication number CN113802790A, which discloses an assembled integrated rock board and its preparation method and application. The assembled integrated rock board is composed of an inorganic board, an adhesive layer and a rock board, wherein the inorganic board is a flame retardant board; Prior art 2 is when the inorganic board is a flame retardant crystal board, which combines the advantages of the rock board and the flame retardant crystal board. Both the rock board and the flame retardant crystal board have the advantages of fire resistance and high temperature resistance, and can achieve A1-level fire resistance. However, only by using an inorganic board with flame retardant properties as a substrate can a good flame retardant effect be obtained. Its versatility is not strong, and it cannot solve the technical problem that the rock board can be compositely assembled with substrates of multiple types of materials. This limits the application scenarios of the rock board composite board, so that it cannot be used in scenes such as ceilings, floors, walls, doors and cabinets at the same time.

[0007] That is, the existing technology is still unable to simultaneously solve the technical problems of stone slabs being able to be composited and assembled with substrates of various types of materials, and at the same time meeting the requirements of high bonding performance, good flame retardant properties, easy processing, and increasing the application surface of stone slabs. Summary of the Invention

[0008] The technical problem to be solved by the present invention is to provide an assembled rock slab and a preparation method thereof, which can enable the rock slab to effectively bond to a variety of different substrates, have good bonding performance, have an ideal flame retardant effect, make the rock slab easy to process, and increase the application surface of the rock slab.

[0009] In order to solve the above technical problems, the present invention provides a method for preparing an assembled rock slab, comprising the following steps:

[0010] (1) Sandblast the back of the rock plate;

[0011] (2) Apply adhesive to the back of the sandblasted rock slab;

[0012] (3) Lay the rock plate coated with the adhesive on the substrate, and then apply local pressure to initially bond the rock plate and the substrate;

[0013] (4) statically pressing the entire surface of the initially bonded rock slab and substrate to obtain a pre-finished product;

[0014] (5) Processing the primary finished product to obtain a finished assembled rock slab.

[0015] As an improvement to the above solution, step (1) includes:

[0016] Performing a first sandblasting treatment on the back side of the rock slab using a first sand;

[0017] Performing a second sandblasting treatment on the back of the rock slab after the first sandblasting treatment using a second sand;

[0018] Performing a third sandblasting treatment on the back of the rock slab after the second sandblasting treatment using a third sand;

[0019] The particle size of the first sand is smaller than the particle size of the second sand, the particle size of the second sand is larger than the particle size of the third sand, and the particle size of the first sand is smaller than the particle size of the third sand.

[0020] As an improvement to the above solution, the particle size of the first sand is 0.05-0.3 mm;

[0021] The particle size of the second sand is 0.5-0.9 mm;

[0022] The particle size of the third sand is 0.25-0.45 mm.

[0023] As an improvement to the above solution, in the first sandblasting process, the angle between the sand nozzle and the back of the rock slab is 75-95°;

[0024] During the second sandblasting process, the angle between the sand nozzle and the back of the rock plate is 30-50°;

[0025] In the third sandblasting process, the angle between the sand nozzle and the back of the rock slab is 65-85°.

[0026] As an improvement to the above solution, in step (2), an adhesive is applied to the back of the rock plate by a glue spraying process, wherein the movement direction of the glue spraying is perpendicular to the movement direction of the rock plate, and the speed of the glue spraying movement is 2-2.5 times the movement speed of the rock plate;

[0027] The shape of the adhesive after the glue is sprayed is a diamond mesh structure, and a distance of 15-30 mm is reserved between the edge of the diamond mesh structure and the edge of the rock slab, and the height of the diamond mesh structure is 5-9 mm.

[0028] As an improvement of the above solution, the adhesive includes component A and component B, wherein component A is mainly made of the following raw materials in parts by weight: 80-120 parts of epoxy resin, 12-25 parts of polyvinyl chloride sol, 1-5 parts of polyether polyol, 5-15 parts of glass powder and 25-55 parts of ceramic powder;

[0029] The B component is mainly made of the following raw materials in parts by weight: 90-110 parts of inorganic acid and 110-135 parts of curing agent.

[0030] The weight ratio of the A component to the B component is (6-10):(1-3).

[0031] As an improvement to the above solution, the chemical composition of the ceramic powder includes, by mass percentage:

[0032] SiO2 4~10%, Al2O3 18~25%, Na2O 17~25%, K2O 13~22%, P2O5 38~48%.

[0033] As an improvement of the above solution, the glass powder includes the following chemical components in percentage by mass: SiO2 68-75%, Al2O3 0.5-1%, Fe2O3 0.07-0.12%, CaO 7.5-9.5%, MgO 3-4.5%, Na2O 13-16%, TiO2 0.03-0.05%, K2O 0.1-0.3% and loss on ignition 0.5-1%.

[0034] As an improvement to the above solution, in the component A, the epoxy value of the epoxy resin is 0.4-0.55;

[0035] The polyether polyol is one or more of polyether polyols 4110, 330, 360, and 3050;

[0036] The polyvinyl chloride sol is prepared by mixing dioctyl phthalate and polyvinyl chloride in a mass ratio of 12:(2-4);

[0037] In the B component, the inorganic acid is one or more of phosphoric acid, hydrochloric acid, and nitric acid;

[0038] The curing agent is one or more of boron trifluoride-tetrahydrofuran complex, 2-methylimidazole, and polyamide.

[0039] As an improvement to the above solution, before step (2), the following is further included:

[0040] The sandblasted rock slab is subjected to surface activation treatment using component C, wherein the component C comprises 90-110 parts of a coupling agent and 4-12 parts of an adhesion promoter.

[0041] As an improvement of the above solution, the coupling agent is one or more of vinyl silane coupling agent, amino hydrocarbon silane coupling agent, epoxy silane coupling agent, and methacryloxy silane coupling agent;

[0042] The adhesion promoter is one or more of butanone, cyclohexanone, dichloroethane, tetrahydrofuran, benzene, and carbon tetrachloride.

[0043] As an improvement to the above scheme, in step (3), the rock plate and the substrate are initially bonded by a local pressing method using a pressing device, wherein the pressing pressure is 2-6 MPa and the number of pressing times is 3-6 times;

[0044] The pressing device has a plurality of pressing points, and the lateral distance between each pressing point is 15-30 cm, and the longitudinal distance between each pressing point is 25-40 cm.

[0045] As an improvement to the above solution, in step (4), the static pressure of the entire surface of the rock plate and the substrate is 20-35 MPa, and the pressure is maintained for 1-2 hours.

[0046] As an improvement to the above solution, in step (5), the processing includes one or more of the following

[0047] A. cutting the pre-finished product;

[0048] B. performing a hole-opening process on the pre-finished product;

[0049] C. slotting the pre-finished product;

[0050] D. Forming or installing structural parts on the pre-finished product.

[0051] As an improvement of the above solution, the substrate is one of bamboo charcoal fiberboard, cement fiberboard, honeycomb board, calcium silicate board, foamed ceramic board and metal board.

[0052] Correspondingly, the present invention also discloses an assembled rock slab, which is prepared by the above-mentioned method for preparing the assembled rock slab.

[0053] The implementation of the present invention has the following beneficial effects:

[0054] The present invention discloses an assembled rock slab and its preparation method. The assembled rock slab is obtained by sandblasting, gluing, pressing with local top pressure and statically pressing the entire surface of the rock slab. This method makes the rock slab easy to process and increases the application surface of the rock slab. Moreover, this method can effectively bond the rock slab to a variety of different substrates, with good bonding performance and ideal flame retardant effect. Specifically,

[0055] (1) The present invention performs sandblasting on the back of the rock plate to maximize the roughness of the back of the rock plate and maximize the efficiency of sandblasting, laying the foundation for the subsequent bonding of the rock plate and the substrate;

[0056] (2) The adhesive used in the present invention can improve the composite tensile and shear strength of the board. After the board is composited, the bonding strength is strong, the impact strength is enhanced, and it can avoid falling off, with low safety risks. In addition, the adhesive has excellent resistance to alternating hot and cold temperatures and aging resistance. Through the low-temperature ceramicization effect of the inorganic material, it can be fired into ceramics at low temperatures, forming an excellent flame retardant effect.

[0057] (3) The present invention uses local top pressure to initially bond the rock slab and the substrate, and then applies static pressure on the entire surface, which can prevent gaps from being left in the middle when the rock slab and the substrate are attached. The air inside can be pressed out through back-and-forth local top pressure, so that the rock slab and the substrate are firmly bonded, effectively improving the bonding strength of the assembled rock slab.

[0058] (4) The composite board of the present invention after local top pressure and whole-surface static pressure improves the machinability of the rock board. The composite rock board will not produce cutting cracks after any cutting. It is safe to construct and use, has a high yield rate, and can be processed in a variety of ways to replace more decorative boards.

[0059] The finished assembled rock slabs of the present invention can be applied to scenes such as ceilings, floors, walls, doors and cabinets, greatly increasing the application surface of the rock slabs, solving the pain points of traditional decoration, eliminating the use of tiles, wallpaper, and paint, and basically containing no formaldehyde, benzene, and radioactive elements. The installation is quick and time-saving, and the construction is water-free and ash-free. BRIEF DESCRIPTION OF THE DRAWINGS

[0060] Figure 1 It is a structural schematic diagram of the top pressure point and the assembled rock slab of the present invention. DETAILED DESCRIPTION

[0061] In order to make the objectives, technical solutions and advantages of the present invention more clear, the present invention will be further described in detail with reference to specific embodiments below.

[0062] The present invention provides a method for preparing an assembled rock slab, comprising the following steps:

[0063] S1: Sandblast the back of the rock slab;

[0064] Preferably, step S1 includes:

[0065] Performing a first sandblasting treatment on the back side of the rock slab using a first sand;

[0066] Performing a second sandblasting treatment on the back of the rock slab after the first sandblasting treatment using a second sand;

[0067] Performing a third sandblasting treatment on the back of the rock slab after the second sandblasting treatment using a third sand;

[0068] The particle size of the first sand is smaller than that of the second sand, the particle size of the second sand is larger than that of the third sand, and the particle size of the first sand is smaller than that of the third sand. The combination of sands with these particle sizes can make the roughness of the back of the stone slab more uniform, thereby effectively improving the bonding performance of the assembled stone slab.

[0069] In addition to using different sand particle size ratios, the present invention also provides for using sand nozzles at different angles during different sandblasting processes. Preferably, in the first sandblasting process, the angle between the sand nozzle and the back of the rock slab is 75-95°; in the second sandblasting process, the angle between the sand nozzle and the back of the rock slab is 30-50°; and in the third sandblasting process, the angle between the sand nozzle and the back of the rock slab is 65-85°.

[0070] The present invention uses three sandblasting processes with different sandblasting angles and different particle sizes. Firstly, the roughness of the back of the rock slab is maximized, and the efficiency of sandblasting is highest. Secondly, it is easier to discharge air when the rock slab is subsequently bonded to the substrate, preventing air from forming between the assembled rock slabs, thereby improving the bonding performance.

[0071] As a preferred specific implementation of step S1, step S1 includes:

[0072] S11: performing a first sandblasting treatment on the back of the rock slab using the first sand;

[0073] The particle size of the first sand is 0.05-0.3 mm, and can be 0.05 mm, 0.1 mm, 0.15 mm, 0.18 mm, 0.2 mm, 0.25 mm, or 0.3 mm, but is not limited thereto. Preferably, the particle size of the first sand is 0.1-0.2 mm.

[0074] Furthermore, in step S11, the angle between the sand nozzle and the back of the rock slab is 75-95°, illustratively 75°, 80°, 85°, 90°, and 95°, but not limited thereto. Since the particle size of the first sand is small and the impact force is small, the present invention adopts a specific sand nozzle with an angle of 75-95° to the back of the rock slab, which is more conducive to the preliminary roughening of the back of the rock slab, laying the foundation for increasing the friction of the back of the rock slab for the second sandblasting treatment, thereby improving the sandblasting effect. Preferably, in step S11, the angle between the sand nozzle and the back of the rock slab is 80-95°.

[0075] S12: using a second sand to perform a second sandblasting on the back of the rock plate after the first sandblasting;

[0076] The particle size of the second sand is 0.5-0.9 mm, and can be 0.5 mm, 0.55 mm, 0.6 mm, 0.65 mm, 0.7 mm, 0.75 mm, 0.8 mm, 0.85 mm, or 0.9 mm, but is not limited thereto. Preferably, the particle size of the second sand is 0.6-0.8 mm.

[0077] Furthermore, in step S12, the angle between the sand nozzle and the back of the rock slab is 30-50°, and examples thereof may be 30°, 35°, 40°, 45°, and 50°, but are not limited thereto. Since the particle size of the second sand is relatively large and the impact force is large, the present invention adopts a specific sand nozzle with an angle of 30-50° between the back of the rock slab, so that when the sand hits the rock slab, it is easy to knock off the aluminum oxide powder on the rock slab, and at the same time, it is easier to make the back of the rock slab rougher; in addition, the vertical force on the rock slab is reduced, and the rock slab is not easy to break. If the angle between the sand nozzle and the back of the rock slab is less than 30°, the friction between the sand and the rock slab is small, and it is not easy to knock off the aluminum oxide powder on the rock slab; if the angle between the sand nozzle and the back of the rock slab is 50-90°, the rock slab is subjected to too much vertical sandblasting force, and it is easy to break for ultra-thin rock slabs (1mm). Preferably, in step S12, the angle between the sand nozzle and the back of the rock slab is 35-45°.

[0078] S13: using a third sand to perform a third sandblasting on the back of the rock plate after the second sandblasting;

[0079] The particle size of the third sand is 0.25-0.45 mm, and can be 0.25 mm, 0.3 mm, 0.35 mm, 0.4 mm, or 0.45 mm, but is not limited thereto. Preferably, the particle size of the second sand is 0.3-0.4 mm. The third sandblasting process employed in the present invention is based on the second sandblasting process, further improving the roughness of the back of the rock slab to compensate for the lack of the second sandblasting process, thereby making the roughness of the back of the rock slab more uniform; at the same time, it can effectively clean the rough surface of the back of the rock slab.

[0080] Furthermore, in step S13, the angle between the sand nozzle and the back of the rock slab is 65-85°, exemplified by, but not limited to, 65°, 70°, 75°, 80°, and 85°. Because the third sand has a smaller particle size and a smaller impact force, using a specific sand nozzle at an angle of 65-85° to the back of the rock slab is more conducive to the sand deeply roughening the rock slab, thereby further improving the roughness of the back of the rock slab. Preferably, in step S13, the angle between the sand nozzle and the back of the rock slab is 70-80°.

[0081] S2: Apply adhesive to the back of the sandblasted rock slab;

[0082] In step S2, adhesive is preferably coated on the back of the rock slab through a glue spraying process, wherein the movement direction of the glue spraying is perpendicular to the movement direction of the rock slab, and the speed of the glue spraying movement is 2-2.5 times the movement speed of the rock slab. This can effectively ensure that the amount of adhesive coated reaches the amount required for bonding.

[0083] Further preferably, the adhesive after glue application is in the form of a diamond-shaped mesh structure, with a 15-30mm gap between the edges of the diamond-shaped mesh structure and the edges of the rock slab, and a height of 5-9mm. This ensures that when the assembled rock slab is pressed, the adhesive can be evenly spread over the entire surface of the rock slab, leaving no gaps between the rock slab and the substrate, while minimizing the amount of adhesive used. More preferably, a 20-25mm gap is reserved between the edges of the diamond-shaped mesh structure and the edges of the rock slab; the thickness of the diamond-shaped mesh structure is 6-8mm.

[0084] The present invention controls the amount and thickness of the adhesive coating and the distance reserved from the edge of the rock slab, so that a sufficient amount of adhesive is left between the assembled rock slabs, thereby effectively ensuring that the resulting assembled rock slabs have better bonding strength and better flame retardant properties.

[0085] Furthermore, the present invention selects a specific adhesive to simultaneously solve the problems of effectively bonding a variety of different substrates, having good bonding performance, and having an ideal flame retardant effect.

[0086] Specifically, the adhesive includes component A and component B; wherein component A is mainly made of the following raw materials in parts by weight: 80-120 parts of epoxy resin, 12-25 parts of polyvinyl chloride sol, 1-5 parts of polyether polyol, 5-15 parts of glass powder and 25-55 parts of ceramic powder; component B is mainly made of the following raw materials in parts by weight: 90-110 parts of inorganic acid and 110-135 parts of curing agent.

[0087] Preferably, component A is mainly made of the following raw materials in parts by weight: 90-110 parts of epoxy resin, 15-20 parts of polyvinyl chloride sol, 2-3 parts of polyether polyol, 8-10 parts of glass powder and 30-50 parts of ceramic powder; component B is mainly made of the following raw materials in parts by weight: 95-105 parts of inorganic acid and 118-130 parts of curing agent.

[0088] More preferably, component A is mainly made of the following raw materials in parts by weight: 95-105 parts of epoxy resin, 16-18 parts of polyvinyl chloride sol, 2-3 parts of polyether polyol, 8-10 parts of glass powder and 35-45 parts of ceramic powder; component B is mainly made of the following raw materials in parts by weight: 95-105 parts of inorganic acid and 120-130 parts of curing agent.

[0089] The weight ratio of component A to component B is (6-10):(1-3). By mixing components A and B in the above ratio, an adhesive can be obtained, which can effectively bond a variety of substrates and has good bonding performance. Preferably, the weight ratio of component A to component B is (8-10):(1-2). More preferably, the weight ratio of component A to component B is (8-9):2.

[0090] Component A includes epoxy resin, polyvinyl chloride sol, polyether polyol, glass powder, and ceramic powder, while component B includes an inorganic acid and a curing agent. The adhesive used in this invention is an environmentally friendly, formaldehyde-free epoxy adhesive that improves the composite tensile and shear strength of the assembled rock slab. After the rock slab is composited with the substrate, the bond strength is strong, impact resistance is enhanced, and disbonding is prevented, minimizing safety risks. Furthermore, the adhesive exhibits excellent resistance to thermal cycling and aging.

[0091] Secondly, the low-temperature porcelain-forming effect of the inorganic material in component A can be fired into ceramics at low temperatures, thus forming an excellent flame retardant effect.

[0092] Again, this application optimizes the specific composition of component A and component B, so that it can effectively bond a variety of different substrates, such as the composite between rock boards and bamboo charcoal fiber boards, cement fiber boards, honeycomb boards, calcium silicate boards, foamed ceramic boards or metal boards, etc., solving technical problems such as the single application of adhesives and meeting the requirements of green, low-carbon and environmental protection.

[0093] Specifically, in component A, epoxy resin is the main matrix component, which can be compounded with polyether polyol to form a stable and uniform matrix system. The amount of epoxy resin used is 80-120 parts, and exemplary amounts include 80 parts, 85 parts, 90 parts, 95 parts, 100 parts, 105 parts, 110 parts, 115 parts, and 120 parts, but are not limited thereto.

[0094] Preferably, in the present invention, the epoxy resin has an epoxy value of 0.4-0.55 (100 g / g), exhibiting advantages such as good adhesion, corrosion resistance, insulation, and high strength. It can synergize well with polyvinyl chloride sol, polyether polyol, glass powder, and ceramic powder to ensure the performance of the adhesive. As an optional embodiment, the epoxy resin is epoxy resin E51, but is not limited thereto.

[0095] The polyvinyl chloride sol is prepared by mixing dioctyl phthalate and polyvinyl chloride, and has the advantages of low plasticizing temperature and strong bonding strength. Preferably, the polyvinyl chloride sol is prepared by mixing dioctyl phthalate and polyvinyl chloride in a mass ratio of 12:(2-4).

[0096] More preferably, the polyvinyl chloride sol is prepared by the following method: dioctyl phthalate and polyvinyl chloride in a mass ratio of 12:(2-4) are mixed, heated in a water bath at 60-80°C and stirred at a stirring speed of 400-1500 rpm for 0.5-2h to obtain the polyvinyl chloride sol.

[0097] The invention prepares polyvinyl chloride sol by adopting dioctyl phthalate and polyvinyl chloride in a specific ratio, which can effectively improve the mechanical properties, heat resistance, processing properties and stability of the polyvinyl chloride sol, and further effectively improve the bonding properties and thermal stability of the obtained adhesive.

[0098] The amount of polyvinyl chloride sol used is 12-25 parts, and exemplary amounts include 12 parts, 13 parts, 14 parts, 15 parts, 17 parts, 18 parts, 19 parts, 20 parts, 21 parts, 22 parts, 23 parts, 24 parts, and 25 parts, but is not limited thereto.

[0099] The polyether polyol is preferably one or more of polyether polyols 4110, 330, 360, and 3050, preferably polyether polyol 330. Epoxy resins are widely used in structural materials, coatings, insulating materials, adhesives, and other fields due to their excellent bonding ability, mechanical properties, chemical stability, and processability. However, epoxy resins are brittle and prone to cracking after cross-linking and curing, and have poor impact resistance. The present invention utilizes specific polyether polyols to effectively address these issues, effectively improving the bond strength of the epoxy resin and, consequently, the resulting adhesive.

[0100] The amount of polyether polyol used is 1-5 parts, and illustratively can be 1 part, 1.5 parts, 2 parts, 2.5 parts, 3 parts, 3.5 parts, 4 parts, 5 parts, but is not limited thereto.

[0101] The present invention also incorporates 5-15 parts of glass powder and 25-55 parts of ceramic powder into component A. The glass powder acts as a support, preventing the adhesive from being squeezed out when pressure is applied, thereby improving the tensile and shear strength of the composite board. The ceramic powder can be formed into porcelain at low temperatures, resulting in excellent flame retardancy.

[0102] Preferably, the chemical composition of the ceramic powder comprises, by mass percentage, 4-10% SiO2, 18-25% Al2O3, 17-25% Na2O, 13-22% K2O, and 38-48% P2O5.

[0103] SiO2 4-10% has a melting and encapsulating effect; Al2O3 18-25% can reduce fluidity and prevent the powder from spreading out in a short time; Na2O 17-25%, K2O 13-22%, and P2O5 38-48% work together to lower the melting temperature.

[0104] The present invention selects the ceramic powder of the above composition, which has a low SiO2 content, a high Al2O3, Na2O and K2O content, and is combined with a high content of P2O5, so that it can be used for bonding rock slabs. The above ceramic powder can be formed into porcelain at low temperature, which can effectively reduce the melting temperature of the ceramic powder. It begins to melt at 300-320°C. When the temperature reaches 300°C, the other materials of the present invention will form ceramics along with the ceramic powder, thereby achieving a flame retardant effect, which can greatly improve the flame retardant performance of the adhesive. The flame retardant grade of the assembled rock slab of the present invention is Class A, and the reference standard is "GB 8624-2012 Classification of Combustion Performance of Building Materials and Products".

[0105] The present invention uses ceramic powder with the above-mentioned specific chemical composition to improve the thermal stability of the adhesive and further enhance the bonding strength. If the content of the ceramic powder is not within the specified range, the thermal stability and bonding strength of the resulting adhesive will deteriorate.

[0106] More preferably, in the ceramic powder, the mass ratio of P2O5 to Al2O3 is (1.7-2.2):1, which can improve the thermal stability of the adhesive and thus improve the flame retardant properties of the adhesive.

[0107] The amount of ceramic powder used is 25-55 parts, and exemplary amounts include 25 parts, 28 parts, 30 parts, 32 parts, 35 parts, 40 parts, 42 parts, 45 parts, 48 ​​parts, 50 parts, 52 parts, and 55 parts, but are not limited thereto. Preferably, the amount of ceramic powder used is 30-50 parts. Furthermore, the fineness of the ceramic powder is preferably 150-350 mesh, more preferably 200-300 mesh.

[0108] Preferably, the glass powder comprises the following chemical components by mass percentage: SiO2 68-75%, Al2O3 0.5-1%, Fe2O3 0.07-0.12%, CaO 7.5-9.5%, MgO 3-4.5%, Na2O 13-16%, TiO2 0.03-0.05%, K2O 0.1-0.3% and loss on ignition 0.5-1%.

[0109] The present invention selects glass powder with a specific chemical composition, which can play a good supporting role when the plates are composited. It has great mechanical strength and can withstand a certain mechanical impact force. Therefore, when pressure is applied, the composite material between the plates will not be squeezed due to the pressure, ensuring that a certain amount of composite glue is retained between the plates. At the same time, the combination of ceramic powder with a specific component makes the bonding strength of the plates using the composite material excellent.

[0110] When high-temperature flame retardancy occurs, the glass powder contains 68-75% SiO2, which can better combine with the ceramic powder when exposed to high temperatures; 0.5-1% Al2O3, which can reduce fluidity; and 7.5-9.5% CaO, 3-4.5% MgO, 0.1-0.3% K2O and 13-16% Na2O, which can be combined with the ceramic powder to reduce the melting temperature.

[0111] The amount of glass powder used is 5-15 parts, and exemplary amounts include 5 parts, 6 parts, 7 parts, 8 parts, 9 parts, 10 parts, 11 parts, 12 parts, 13 parts, 14 parts, and 15 parts, but is not limited thereto. Furthermore, the fineness of the glass powder is preferably 40-150 mesh, more preferably 60-100 mesh, which helps ensure that the adhesive has good mechanical strength, thereby ensuring good bonding strength of the assembled rock slab using the adhesive.

[0112] Further, component A is prepared by the following method:

[0113] stirring and mixing the epoxy resin, polyvinyl chloride sol, polyether polyol, glass powder and ceramic powder at a first stirring speed to obtain a mixture;

[0114] The mixture was sonicated;

[0115] The ultrasonically treated mixture is stirred and mixed for the second time at a second stirring speed to obtain component A.

[0116] Wherein, the first stirring speed is 400-800 rpm; the second stirring speed is 800-1500 rpm.

[0117] The present invention firstly pre-mixes the raw materials of component A with each other through low-speed stirring, then improves the dispersion through ultrasonic treatment, and finally achieves the best dispersion uniformity of glass powder and ceramic powder in component A under the action of high-speed stirring, thereby ensuring the various properties of the obtained adhesive.

[0118] In component B of the present invention, the inorganic acid is one or more of phosphoric acid, hydrochloric acid, and nitric acid. Preferably, the inorganic acid is phosphoric acid. The amount of the inorganic acid used is 90-110 parts, and exemplary amounts include 90 parts, 92 parts, 95 parts, 97 parts, 100 parts, 102 parts, 105 parts, 108 parts, and 110 parts, but are not limited thereto.

[0119] The amount of curing agent used is 110-135 parts, and exemplary amounts include 110 parts, 112 parts, 115 parts, 118 parts, 120 parts, 122 parts, 124 parts, 125 parts, 128 parts, 130 parts, 131 parts, 133 parts, and 135 parts, but are not limited thereto.

[0120] Specifically, the curing agent is one or more of boron trifluoride-tetrahydrofuran complex, 2-methylimidazole, and polyamide, but is not limited thereto. Preferably, the curing agent includes boron trifluoride-tetrahydrofuran complex, 2-methylimidazole, and polyamide, and the ratio of the added amount of the boron trifluoride-tetrahydrofuran complex, 2-methylimidazole, and polyamide is (68-82): (40-50): (2-6). The use of the above curing agent can improve the composite bonding strength of the rock board to materials such as PVC or PP.

[0121] As an optional embodiment, the polyamide may be polyamide 650, but is not limited thereto.

[0122] In summary, the adhesive used in the present invention can effectively bond a variety of different substrates, has good bonding performance, can improve the composite tensile and shear strength of the assembled rock slab, and after the rock slab and the substrate are assembled, the bonding strength is strong, the impact resistance is enhanced, and it prevents falling off, and has an ideal flame retardant effect. After the rock slab is assembled with different substrates using the adhesive of the present invention, the performance is as follows:

[0123]

[0124]

[0125] The testing basis and indicators of the above-mentioned flexural strength, bonding strength and falling ball impact strength refer to "GB / T 29059-2012 Ultra-thin Stone Composite Panel".

[0126] As a better embodiment of the present invention, before step S2, it also includes: using component C to perform surface activation treatment on the sandblasted rock plate, and the component C includes 90-110 parts of a coupling agent and 4-12 parts of an adhesion promoter.

[0127] The coupling agent is one or more of a vinyl silane coupling agent, an aminoalkyl silane coupling agent, an epoxy silane coupling agent, and a methacryloxy silane coupling agent. The amount of the coupling agent is 90-110 parts, and exemplary amounts include 90 parts, 92 parts, 95 parts, 98 parts, 99 parts, 100 parts, 102 parts, 103 parts, 105 parts, 108 parts, and 110 parts, but are not limited thereto. Preferably, the amount of the coupling agent is 95-105 parts.

[0128] Furthermore, the coupling agent is a composite coupling agent of an epoxy silane coupling agent and an amino hydrocarbon silane coupling agent, and the mass ratio of the epoxy silane coupling agent to the amino hydrocarbon silane coupling agent is 1:(2-3), which can further improve the bonding performance between the rock slab and the adhesive.

[0129] The adhesion promoter is one or more of butanone, cyclohexanone, ethylene dichloride, tetrahydrofuran, benzene, and carbon tetrachloride. The amount of the adhesion promoter is 4-12 parts, and exemplary amounts include 4 parts, 5 parts, 6 parts, 7 parts, 8 parts, 9 parts, 10 parts, 11 parts, and 12 parts, but are not limited thereto. Preferably, the amount of the adhesion promoter is 5-10 parts.

[0130] Specifically, the specific preparation method of component C is as follows: mixing the coupling agent and the adhesion promoter, and stirring at a stirring speed of 400-1500 rpm for 0.5-2 hours to obtain the product.

[0131] The present invention can further improve the bonding performance of the rock slab and the adhesive by coating component C on the back of the rock slab after sandblasting, and then using components A and B to bond the rock slab to the substrate, thereby further improving the bonding strength of the assembled rock slab.

[0132] S3: Lay the rock slab coated with adhesive on the substrate, and then apply local pressure to achieve initial adhesion between the rock slab and the substrate;

[0133] Specifically, in step S3, a local pressing method is used through a pressing device to initially bond the rock slab and the substrate, wherein the pressing pressure is 2-6 MPa and the number of pressings is 3-6 times; the pressing device has multiple pressing points, and the lateral distance between each pressing point is 15-30 cm, and the longitudinal distance is 25-40 cm.

[0134] like Figure 1 As shown, in some embodiments of the present technical solution, there are multiple rows of top pressure points 1, each row is provided with multiple top pressure points 1, and they are evenly arranged on the assembled rock slab 2. The distance between each row of top pressure points 1 is 20-25 cm, and the distance between two rows of top pressure points 1 is 30-35 cm.

[0135] The present invention adopts a local top pressing method, which can prevent the rock plate and the substrate from leaving a gap between them when they are attached, resulting in a weak adhesion between the rock plate and the substrate, thereby effectively improving the bonding strength of the assembled rock plate. If a conventional rolling process is used, a local vacuum is easily formed between the rock plate and the substrate, resulting in a gap between the rock plate and the substrate when they are attached, resulting in a weak adhesion between the rock plate and the substrate.

[0136] Furthermore, in order to prevent excessive pressure from the local top pressure method, the pressure can be relieved by adjusting the spring provided on the top pressure device, so as to ensure that the force on the rock plate and the substrate is uniform and stable.

[0137] It should be noted that the substrate is preferably one of bamboo charcoal fiberboard, cement fiberboard, honeycomb board, calcium silicate board, foamed ceramic board, and metal board, but is not limited thereto. The adhesive and composite process of the present invention can achieve firm bonding between rock board and substrates of various materials, such as bamboo charcoal fiberboard, cement fiberboard, honeycomb board, calcium silicate board, foamed ceramic board, and metal board. This can improve the composite tensile and shear strength of the board, prevent cracking or falling off after a falling ball impact, and withstand 6 to 8 hot and cold cycling tests at temperatures ranging from -18°C to 200°C without peeling or cracking. The flame retardant performance reaches A1 level, and the safety performance is excellent.

[0138] S4: statically press the entire surface of the preliminarily bonded rock slab and substrate to obtain a pre-finished product;

[0139] Specifically, in step S4, the pressure of the rock slab and the substrate being statically pressed over the entire surface is 20-35 MPa, and the pressure is maintained for 1-2 hours. The assembled rock slab of the present invention adopts a combination of local top pressure and static pressure over the entire surface, which can further improve the composite tensile and shear strength of the rock slab and the substrate, forming an assembled rock slab with good impact resistance and bonding strength. Preferably, the assembled rock slab is kept under a pressure of 25-30 MPa for 1-1.5 hours.

[0140] S5: Processing the primary finished product to obtain a finished assembled rock slab.

[0141] Specifically, in step S5, the processing includes one or more of the following:

[0142] A. cutting the pre-finished product;

[0143] B. performing a hole-opening process on the pre-finished product;

[0144] C. slotting the pre-finished product;

[0145] D. Forming or installing structural parts on the pre-finished product.

[0146] The above process can improve the machinability of the rock slab, and any cuts and holes will not produce cracks. Moreover, the cuts and holes can be cut in various shapes, which can meet the cutting and hole requirements of complex and special patterns.

[0147] After cutting or drilling, the structural components can be slotted or welded together according to the requirements of the installed structure. For example, when a rock slab is combined with bamboo charcoal fiberboard, PVC board, cement fiberboard, calcium silicate board, foam board, or magnesium board, slots or holes can be cut to form the installed structural component. When a rock slab is combined with a metal sheet (such as aluminum or stainless steel), welding can be performed on the structural component.

[0148] Therefore, the present invention enables diversified processing, safe construction and use, high yield, and expands the application area of ​​rock slabs to replace more decorative panels. The finished assembled rock slabs of the present invention can be applied to scenes such as ceilings, floors, walls, doors, and cabinets, solving the pain points of traditional decoration, eliminating the use of tiles, wallpaper, and paint. They are essentially formaldehyde-free, benzene-free, and radioactive elements, and can be installed quickly and labor-savingly, with water-free and ash-free construction.

[0149] For example: rock slabs composite lightweight boards (bamboo charcoal fiber boards, honeycomb boards) can be applied to walls, doors, cabinets, cabinet doors, and countertops after assembly; rock slabs composite cement fiber boards and calcium silicate boards can be applied to the floor after assembly; rock slabs composited with different materials can meet the processing needs of different application scenarios after assembly.

[0150] Correspondingly, the present invention also discloses an assembled rock slab, which is prepared by the above-mentioned preparation method of the assembled rock slab.

[0151] The present invention will be further described below with specific embodiments:

[0152] Example 1

[0153] A method for preparing an assembled rock slab comprises the following steps:

[0154] (1) Sandblast the back of the rock plate;

[0155] (2) Apply adhesive to the back of the sandblasted rock slab through a glue spraying process;

[0156] (3) The rock plate coated with the adhesive on one side is laminated to the substrate, and then the rock plate and the substrate are initially bonded by a local pressing method using a pressing device, wherein the pressing pressure is 3 MPa and the number of pressings is 3 times; the pressing device has multiple pressing points, and the horizontal distance between each pressing point is 25 cm and the vertical distance is 30 cm;

[0157] (4) The rock plate and the substrate after preliminary bonding are subjected to static pressure on the entire surface at a pressure of 22 MPa and maintained at this pressure for 1.5 hours to obtain the primary finished product;

[0158] (5) Processing the primary finished product to obtain a finished assembled rock slab.

[0159] The adhesive comprises component A and component B; the weight ratio of component A to component B is 3:1;

[0160] Component A is made from the following raw materials: 80 g of epoxy resin E51, 12 g of polyvinyl chloride sol, 1 g of polyether polyol 330, 5 g of glass powder, and 25 g of ceramic powder;

[0161] Component B is prepared from the following raw materials: 95 g of phosphoric acid, 68 g of boron trifluoride-tetrahydrofuran complex, 41 g of 2-methylimidazole, and 2 g of polyamide 650.

[0162] The chemical composition of ceramic powder is SiO2 11%, Al2O3 13%, Na2O 16%, K2O 23%, P2O5 37%.

[0163] The chemical composition of the glass powder is SiO2 72%, Al2O3 0.8%, Fe2O3 0.1%, CaO 8.5%, MgO3.6%, Na2O 14%, TiO2 0.04%, K2O 0.2% and loss on ignition 0.76%.

[0164] The preparation method of the adhesive is:

[0165] (1) The epoxy resin, polyvinyl chloride sol, polyether polyol, glass powder, and ceramic powder were mixed, stirred at a stirring speed of 400-800 rpm for 2.5 hours, ultrasonically treated for 2 hours, and then stirred at a stirring speed of 800-1500 rpm for 3.5 hours to obtain component A;

[0166] (2) Mix phosphoric acid and curing agent and stir for 1 hour to obtain component B;

[0167] (3) Mix component A and component B in proportion to obtain an adhesive.

[0168] Example 2

[0169] A method for preparing an assembled rock slab comprises the following steps:

[0170] (1) Sandblast the back of the rock plate;

[0171] (2) Apply adhesive to the back of the sandblasted rock slab through a glue spraying process;

[0172] (3) The rock plate coated with the adhesive is laminated to the substrate, and then the rock plate and the substrate are initially bonded by a local pressing method using a pressing device, wherein the pressing pressure is 2.5 MPa and the number of pressings is 4; the pressing device has multiple pressing points, and the horizontal distance between each pressing point is 25 cm and the vertical distance is 30 cm;

[0173] (4) The rock plate and the substrate after preliminary bonding are subjected to static pressure on the entire surface at a pressure of 30 MPa and maintained at this pressure for 1 hour to obtain the primary finished product;

[0174] (5) Processing the primary finished product to obtain a finished assembled rock slab.

[0175] The adhesive comprises component A and component B; the weight ratio of component A to component B is 4:1;

[0176] Component A is made from the following raw materials: 90g of epoxy resin E51, 15g of polyvinyl chloride sol, 2g of polyether polyol 330, 10g of glass powder, and 30g of ceramic powder;

[0177] Component B is prepared from the following raw materials: 100 g of phosphoric acid, 70 g of boron trifluoride-tetrahydrofuran complex, 45 g of 2-methylimidazole, and 2 g of polyamide 650.

[0178] The chemical composition of ceramic powder is SiO2 7%, Al2O3 19%, Na2O 18%, K2O 14%, and P2O5 42%.

[0179] The chemical composition of the glass powder is SiO2 70.53%, Al2O3 1%, Fe2O3 0.12%, CaO 9%, MgO 3%, Na2O 15%, TiO2 0.05%, K2O 0.3% and loss on ignition 1%.

[0180] The preparation method of the adhesive is:

[0181] (1) The epoxy resin, polyvinyl chloride sol, polyether polyol, glass powder and ceramic powder were mixed, stirred at a stirring speed of 400-800 rpm for 3 hours, ultrasonically treated for 2 hours, and then stirred at a stirring speed of 800-1500 rpm for 4 hours to obtain component A;

[0182] (2) Mix phosphoric acid and curing agent and stir for 2 hours to obtain component B;

[0183] (3) Mix component A and component B in proportion to obtain an adhesive.

[0184] Example 3

[0185] A method for preparing an assembled rock slab comprises the following steps:

[0186] (1) Sandblast the back of the rock plate;

[0187] (2) Apply adhesive to the back of the sandblasted rock slab through a glue spraying process;

[0188] (3) The rock plate coated with the adhesive is laminated to the substrate, and then the rock plate and the substrate are initially bonded by a local pressing method using a pressing device, wherein the pressing pressure is 4 MPa and the number of pressings is 3; the pressing device has multiple pressing points, and the horizontal distance between each pressing point is 25 cm and the vertical distance is 30 cm;

[0189] (4) The rock plate and the substrate after preliminary bonding are subjected to static pressure on the entire surface at a pressure of 20 MPa and maintained at this pressure for 2 hours to obtain the primary finished product;

[0190] (5) Processing the primary finished product to obtain a finished assembled rock slab.

[0191] The adhesive comprises component A and component B; the weight ratio of component A to component B is 4:1;

[0192] Component A is made from the following raw materials: 100 g of epoxy resin E51, 20 g of polyvinyl chloride sol, 4 g of polyether polyol 330, 12 g of glass powder, and 40 g of ceramic powder;

[0193] Component B is prepared from the following raw materials: 100 g of phosphoric acid, 72 g of boron trifluoride-tetrahydrofuran complex, 50 g of 2-methylimidazole, and 4 g of polyamide 650.

[0194] The chemical composition of ceramic powder is SiO2 7%, Al2O3 18%, Na2O 19%, K2O 14%, and P2O5 42%.

[0195] The chemical composition of the glass powder is SiO2 72%, Al2O3 0.8%, Fe2O3 0.1%, CaO 8.5%, MgO3.6%, Na2O 14%, TiO2 0.04%, K2O 0.2% and loss on ignition 0.76%.

[0196] The preparation method of the adhesive is:

[0197] (1) The epoxy resin, polyvinyl chloride sol, polyether polyol, glass powder and ceramic powder were mixed, stirred at a stirring speed of 400-800 rpm for 1.5 hours, ultrasonically treated for 1.5 hours, and then stirred at a stirring speed of 800-1500 rpm for 3 hours to obtain component A;

[0198] (2) Mix phosphoric acid and curing agent and stir for 1.5 hours to obtain component B;

[0199] (3) Mix component A and component B in proportion to obtain an adhesive.

[0200] Example 4

[0201] A method for preparing an assembled rock slab comprises the following steps:

[0202] (1) The back of the rock plate is subjected to a first sandblasting treatment using sand having a first particle size of 0.2-0.3 mm, with the angle between the sand nozzle and the back of the rock plate being 95°; then, the back of the rock plate subjected to the first sandblasting treatment is subjected to a second sandblasting treatment using sand having a second particle size of 0.8-0.9 mm, with the angle between the sand nozzle and the back of the rock plate being 45°; finally, the back of the rock plate subjected to the second sandblasting treatment is subjected to a third sandblasting treatment using sand having a third particle size of 0.4-0.45 mm, with the angle between the sand nozzle and the back of the rock plate being 85°;

[0203] (2) The adhesive is applied to the back of the sandblasted rock slab by a glue spraying process. The direction of the glue spraying is perpendicular to the direction of the rock slab movement, and the speed of the glue spraying is twice the speed of the rock slab movement. After the glue spraying, the shape of the adhesive is a diamond mesh structure. The edge of the diamond mesh structure is 15 mm away from the edge of the rock slab, and the height of the diamond mesh structure is 5 mm.

[0204] (3) The rock plate coated with the adhesive is laminated to the substrate, and then the rock plate and the substrate are initially bonded by a local pressing method using a pressing device, wherein the pressing pressure is 5 MPa and the number of pressings is 4; the pressing device has multiple pressing points, and the horizontal distance between each pressing point is 25 cm and the vertical distance is 30 cm;

[0205] (4) The rock plate and the substrate after preliminary bonding are subjected to static pressure on the entire surface at a pressure of 35 MPa and maintained at this pressure for 1 hour to obtain the primary finished product;

[0206] (5) Processing the primary finished product to obtain a finished assembled rock slab.

[0207] The adhesive comprises component A and component B; the weight ratio of component A to component B is 4:1;

[0208] Component A was prepared from the following raw materials: 110 g of epoxy resin E51, 22 g of polyvinyl chloride sol, 3303 g of polyether polyol, 15 g of glass powder, and 45 g of ceramic powder;

[0209] Component B is prepared from the following raw materials: 100 g of phosphoric acid, 70 g of boron trifluoride-tetrahydrofuran complex, 50 g of 2-methylimidazole, and 6 g of polyamide 650.

[0210] The chemical composition of ceramic powder is SiO2 7%, Al2O3 20%, Na2O 18%, K2O 13%, and P2O5 42%.

[0211] The chemical composition of the glass powder is SiO2 72%, Al2O3 0.8%, Fe2O3 0.1%, CaO 8.5%, MgO3.6%, Na2O 14%, TiO2 0.04%, K2O 0.2% and loss on ignition 0.76%.

[0212] (2) Preparation method:

[0213] (1) The epoxy resin, polyvinyl chloride sol, polyether polyol, glass powder and ceramic powder were mixed, stirred at a stirring speed of 600-800 rpm for 2 h, ultrasonically treated for 2 h, and then stirred at a stirring speed of 800-1200 rpm for 2 h to obtain component A;

[0214] (2) Mix phosphoric acid and curing agent and stir for 2 hours to obtain component B;

[0215] (3) Mix component A and component B in proportion to obtain an adhesive.

[0216] Example 5

[0217] A method for preparing an assembled rock slab comprises the following steps:

[0218] (1) The back of the rock plate is subjected to the first sandblasting treatment using sand having a first particle size of 0.1-0.2 mm, with the angle between the sand nozzle and the back of the rock plate being 80°; then the back of the rock plate subjected to the first sandblasting treatment is subjected to the second sandblasting treatment using sand having a second particle size of 0.6-0.7 mm, with the angle between the sand nozzle and the back of the rock plate being 38°; finally, the back of the rock plate subjected to the second sandblasting treatment is subjected to the third sandblasting treatment using sand having a third particle size of 0.3-0.4 mm, with the angle between the sand nozzle and the back of the rock plate being 70°;

[0219] (2) The adhesive is applied to the back of the sandblasted rock slab by a glue spraying process. The direction of the glue spraying is perpendicular to the direction of the rock slab movement, and the speed of the glue spraying is 2.5 times the speed of the rock slab movement. After the glue spraying, the shape of the adhesive is a diamond mesh structure. The edge of the diamond mesh structure is 30 mm away from the edge of the rock slab, and the height of the diamond mesh structure is 9 mm.

[0220] (3) The rock plate coated with the adhesive on one side is laminated to the substrate, and then the rock plate and the substrate are initially bonded by a local pressing method using a pressing device, wherein the pressing pressure is 5 MPa and the number of pressings is 6 times; the pressing device has multiple pressing points, and the horizontal distance between each pressing point is 25 cm and the vertical distance is 30 cm;

[0221] (4) The rock plate and the substrate after preliminary bonding are subjected to static pressure on the entire surface at a pressure of 35 MPa and maintained at this pressure for 1 hour to obtain the primary finished product;

[0222] (5) Processing the primary finished product to obtain a finished assembled rock slab.

[0223] The adhesive includes component A and component B; the weight ratio of component A to component B is 4:1.

[0224] Component A is made from the following raw materials: 120 g of epoxy resin E51, 25 g of polyvinyl chloride sol, 3305 g of polyether polyol, 15 g of glass powder, and 55 g of ceramic powder;

[0225] Component B is prepared from the following raw materials: 110 g of phosphoric acid, 80 g of boron trifluoride-tetrahydrofuran complex, 50 g of 2-methylimidazole, and 6 g of polyamide 650.

[0226] The chemical composition of ceramic powder is SiO2 10%, Al2O3 18%, Na2O 17%, K2O 13%, P2O5 42%.

[0227] The chemical composition of the glass powder is SiO2 72.5%, Al2O3 0.8%, Fe2O3 0.1%, CaO 8%, MgO3.0%, Na2O 14.6%, TiO2 0.04%, K2O 0.2% and loss on ignition 0.76%.

[0228] (2) Preparation method:

[0229] (1) The epoxy resin, polyvinyl chloride sol, polyether polyol, glass powder and ceramic powder were mixed, stirred at a stirring speed of 400-800 rpm for 1 hour, ultrasonically treated for 2 hours, and then stirred at a stirring speed of 800-1500 rpm for 2 hours to obtain component A;

[0230] (2) Mix phosphoric acid and curing agent and stir for 2 hours to obtain component B;

[0231] (3) Mix component A and component B in proportion to obtain an adhesive.

[0232] Example 6

[0233] A method for preparing an assembled rock slab comprises the following steps:

[0234] (1) The back of the rock plate is subjected to a first sandblasting treatment using sand having a first particle size of 0.1-0.2 mm, with the angle between the sand nozzle and the back of the rock plate being 85°; then, the back of the rock plate subjected to the first sandblasting treatment is subjected to a second sandblasting treatment using sand having a second particle size of 0.6-0.7 mm, with the angle between the sand nozzle and the back of the rock plate being 40°; finally, the back of the rock plate subjected to the second sandblasting treatment is subjected to a third sandblasting treatment using sand having a third particle size of 0.3-0.4 mm, with the angle between the sand nozzle and the back of the rock plate being 75°;

[0235] (2) Component C is used to perform surface activation treatment on the rock slab after sandblasting, and adhesive is applied to the back of the rock slab treated with component C by a glue spraying process. The movement direction of the glue spraying is perpendicular to the movement direction of the rock slab, and the speed of the glue spraying is 2.3 times the movement speed of the rock slab. The shape of the adhesive after glue spraying is a diamond mesh structure, and a 22 mm gap is reserved between the edge of the diamond mesh structure and the edge of the rock slab. The height of the diamond mesh structure is 8.2 mm;

[0236] (3) The rock plate coated with the adhesive is laminated to the substrate, and then the rock plate and the substrate are initially bonded by a local pressing method using a pressing device, wherein the pressing pressure is 4 MPa and the number of pressings is 3; the pressing device has multiple pressing points, and the horizontal distance between each pressing point is 25 cm and the vertical distance is 30 cm;

[0237] (4) The rock plate and the substrate after preliminary bonding are subjected to static pressure on the entire surface at a pressure of 20 MPa and maintained at this pressure for 2 hours to obtain the primary finished product;

[0238] (5) Processing the primary finished product to obtain a finished assembled rock slab.

[0239] The adhesive comprises component A and component B; the weight ratio of component A to component B is 4:1;

[0240] Component A is made from the following raw materials: 100 g of epoxy resin E51, 20 g of polyvinyl chloride sol, 4 g of polyether polyol 330, 12 g of glass powder, and 40 g of ceramic powder;

[0241] Component B is prepared from the following raw materials: 100 g of phosphoric acid, 72 g of boron trifluoride-tetrahydrofuran complex, 50 g of 2-methylimidazole, and 4 g of polyamide 650.

[0242] The chemical composition of ceramic powder is SiO2 7%, Al2O3 18%, Na2O 19%, K2O 14%, and P2O5 42%.

[0243] The chemical composition of the glass powder is SiO2 72%, Al2O3 0.8%, Fe2O3 0.1%, CaO 8.5%, MgO3.6%, Na2O 14%, TiO2 0.04%, K2O 0.2% and loss on ignition 0.76%.

[0244] Component C was prepared as follows: 30 g of coupling agents KH-560 and 70 g of KH-550 were mixed with 6 g of butanone, and stirred at a rotation speed of 400-1500 rpm for 2 h to obtain component C.

[0245] The preparation method of the adhesive is:

[0246] (1) The epoxy resin, polyvinyl chloride sol, polyether polyol, glass powder and ceramic powder were mixed, stirred at a stirring speed of 400-800 rpm for 1.5 hours, ultrasonically treated for 1.5 hours, and then stirred at a stirring speed of 800-1500 rpm for 3 hours to obtain component A;

[0247] (2) Mix phosphoric acid and curing agent and stir for 1.5 hours to obtain component B;

[0248] (3) Mix component A and component B in proportion to obtain an adhesive.

[0249] (1) Bamboo charcoal fiberboard was selected as the substrate. The bamboo charcoal fiberboard and the rock board were prepared into assembled rock boards using the methods of Examples 1-6. The assembled rock boards were tested for bonding strength and flame retardancy. The results were as follows:

[0250] Table 1 Bonding strength and flame retardant properties of bamboo charcoal fiberboard and rock board

[0251]

[0252]

[0253] (II) Calcium silicate board, bamboo charcoal fiberboard and rock board were selected as the base material to prepare assembled rock board by the method of Examples 1-6, and the assembled rock board was tested for bonding strength and flame retardancy. The results are as follows:

[0254] Table 2 Bonding strength and flame retardant properties of calcium silicate board and rock board

[0255]

[0256] In summary, the preparation method of the assembled rock slab of the present invention enables the rock slab to be effectively bonded to a variety of different substrates, which can improve the composite tensile and shear strength of the assembled rock slab. After the panels are composited, the bonding strength is strong. For bamboo charcoal fiberboard, the flexural strength is ≥12.8MPa, and the bonding strength is ≥1.9MPa. For calcium silicate board, the flexural strength is ≥12.2MPa, and the bonding strength is ≥2.8MPa. Moreover, no cracks or falling will occur after the impact of a falling ball. At low temperatures of -18°C to high temperatures of 200°C, it can withstand 6 to 8 hot and cold alternating tests without peeling or cracking. The flame retardant performance is as high as A1 level, and the safety performance is good.

[0257] It should be noted that the above-mentioned testing methods refer to "GB / T 29059-2012 Ultra-thin Stone Composite Panels" and "GB8624-2012 Classification of Combustion Performance of Building Materials and Products".

[0258] The above disclosure is only a preferred embodiment of the present invention and certainly cannot be used to limit the scope of the present invention. Therefore, equivalent changes made according to the claims of the present invention are still within the scope of the present invention.

Claims

1. A method for preparing an assembled rock slab, characterized in that: The following steps are involved: (1) Sandblast the back of the rock slab; (2) Apply adhesive to the back of the sandblasted rock slab; (3) Lay the rock slab coated with adhesive on one side and the substrate, and then use a pressing device to make the rock slab and the substrate initially bonded by local pressing, wherein the pressing pressure is 2-6 MPa and the number of pressings is 3-6 times; the pressing device has multiple pressing points, and the horizontal distance between each pressing point is 15-30 cm and the vertical distance is 25-40 cm; (4) The rock plate and the base material after preliminary bonding are subjected to static pressing on the entire surface to obtain a preliminary finished product; wherein, the static pressing pressure of the entire surface is 20-35 MPa, and the pressure is maintained for 1-2 hours; (5) processing the primary finished product to obtain a finished assembled rock slab; The adhesive comprises component A and component B, and the weight ratio of component A to component B is (6-10): (1-3); The component A is mainly made of the following raw materials in parts by weight: 80-120 parts of epoxy resin, 12-25 parts of polyvinyl chloride sol, 1-5 parts of polyether polyol, 5-15 parts of glass powder and 25-55 parts of ceramic powder; The B component is mainly made of the following raw materials in parts by weight: 90-110 parts of inorganic acid and 110-135 parts of curing agent; The glass powder comprises the following chemical components by mass percentage: SiO2 68-75%, Al2O3 0.5-1%, Fe2O3 0.07-0.12%, CaO 7.5-9.5%, MgO 3-4.5%, Na2O 13-16%, TiO2 0.03-0.05%, K2O 0.1-0.3% and loss on ignition 0.5-1%; The chemical composition of the ceramic powder includes, by mass percentage: SiO24~10%, Al2O318~25%, Na2O 17~25%, K2O 13~22%, P2O5 38~48%; Wherein, step (1) includes: Performing a first sandblasting treatment on the back of the rock slab using a first sand; wherein the particle size of the first sand is 0.05-0.3 mm; Performing a second sandblasting treatment on the back of the rock slab after the first sandblasting treatment using a second sand; wherein the particle size of the second sand is 0.5-0.9 mm; The back of the rock slab after the second sandblasting treatment is subjected to a third sandblasting treatment using a third sand; wherein the particle size of the third sand is 0.25-0.45 mm.

2. The method for preparing the assembled rock slab according to claim 1, wherein: In the first sandblasting process, the angle between the sand nozzle and the back of the rock slab is 75-95°; During the second sandblasting process, the angle between the sand nozzle and the back of the rock plate is 30-50°; In the third sandblasting process, the angle between the sand nozzle and the back of the rock slab is 65-85°.

3. The method for preparing the assembled rock slab according to claim 1, wherein: In step (2), adhesive is applied to the back of the rock plate by a glue spraying process, wherein the movement direction of the glue spraying is perpendicular to the movement direction of the rock plate, and the speed of the glue spraying movement is 2-2.5 times the movement speed of the rock plate; The shape of the adhesive after the glue is sprayed is a diamond mesh structure, and a distance of 15-30 mm is reserved between the edge of the diamond mesh structure and the edge of the rock slab, and the height of the diamond mesh structure is 5-9 mm.

4. The method for preparing the assembled rock slab according to claim 1, wherein: In the component A, the epoxy value of the epoxy resin is 0.4-0.55; The polyether polyol is one or more of polyether polyols 4110, 330, 360, and 3050; The polyvinyl chloride sol is prepared by mixing dioctyl phthalate and polyvinyl chloride in a mass ratio of 12:(2-4); In the B component, the inorganic acid is one or more of phosphoric acid, hydrochloric acid, and nitric acid; The curing agent is one or more of boron trifluoride-tetrahydrofuran complex, 2-methylimidazole, and polyamide.

5. The method for preparing the assembled rock slab according to claim 1, wherein: Before step (2), it also includes: Component C is used to perform surface activation treatment on the sandblasted rock plate, wherein the component C is made of the following raw materials in parts by weight: 90-110 parts of a coupling agent and 4-12 parts of an adhesion promoter.

6. The method for preparing the assembled rock slab according to claim 5, wherein: The coupling agent is one or more of vinyl silane coupling agent, aminoalkyl silane coupling agent, epoxy silane coupling agent, and methacryloxy silane coupling agent; The adhesion promoter is one or more of butanone, cyclohexanone, dichloroethane, tetrahydrofuran, benzene, and carbon tetrachloride.

7. The method for preparing the assembled rock slab according to claim 1, wherein: In step (5), the processing includes one or more of the following: A. cutting the pre-finished product; B. performing a hole-opening process on the pre-finished product; C. slotting the pre-finished product; D. Forming or installing structural parts on the pre-finished product.

8. The method for preparing the assembled rock slab according to claim 1, wherein: The substrate is one of bamboo charcoal fiberboard, cement fiberboard, honeycomb board, calcium silicate board, foamed ceramic board and metal board.

9. A prefabricated rock slab, characterized in that: It is prepared by the preparation method of the assembled rock slab described in any one of claims 1-8.

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