Preparation process of environment-friendly artificial quartz stone

Abstract

The application discloses an environment-friendly artificial quartz stone preparation process, and the environment-friendly artificial quartz stone comprises the following raw materials: quartz sand, magnesite, granite fiber, wood fiber, hollow glass microbead, pigment, high-alumina clay, resin, curing agent and dispersing agent. By limiting the raw material composition of the artificial quartz stone and cooperating with a specific preparation process, the strength and compressive strength of the prepared artificial quartz stone are improved, the artificial quartz stone can resist the influence of external environment on the performance of the stone, can be used in a high-temperature environment, and the application range of the artificial quartz stone is widened. The wood cellulose is mixed with other raw materials to form a three-dimensional network structure, and the uniformly dispersed hollow glass microbead is cooperated to improve the compressive strength of the prepared artificial quartz stone, and the artificial quartz stone is not prone to cracking and breaking during long-term use.

Description

Technical Field

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

[0002] In the field of architectural decoration, stone has become one of the main decorative materials due to its beauty, elegance, and strong decorative properties. Natural marble has always been widely used because of its rich and natural patterns, decorative effect, and texture. However, due to limited resources, large-scale mining and use will lead to resource depletion. Furthermore, large-area paving has problems such as color difference, excessive radioactivity, low hardness, and easy scratching. Therefore, the widespread use of natural marble in the field of architectural decoration is neither scientific nor environmentally friendly.

[0003] Artificial quartz stone is a synthetic stone manufactured artificially. It is a new type of decorative slab made primarily of quartz crystals, along with resin and a small amount of pigments. It is produced by vacuum vibration pressing under specific physical and chemical conditions using specialized machinery, resulting in large-format slabs. The resulting slabs are harder and denser, possessing unparalleled wear resistance, pressure resistance, high-temperature resistance, corrosion resistance, and impermeability compared to other decorative materials. Consequently, the surface patterns and colors can be precisely controlled, and the appearance can mimic marble and granite, greatly satisfying consumer demands.

[0004] Existing artificial quartz stone has a low heat deformation temperature, generally between 45-55℃. It is prone to deformation at high temperatures, and has poor compressive strength, making it easy to break and crack. Further improvements are needed. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide an environmentally friendly artificial quartz stone preparation process.

[0006] The present invention adopts the following technical solution:

[0007] An environmentally friendly artificial quartz stone preparation process, wherein the environmentally friendly artificial stone comprises the following raw materials in parts by weight: 40-50 parts quartz sand, 22-28 parts magnesite, 10-12 parts granite fiber, 12-16 parts wood fiber, 8-10 parts hollow glass microspheres, 1-2 parts pigment, 8-10 parts high-alumina clay, 5-8 parts resin, 0.3-0.7 parts curing agent, and 2-3 parts dispersant;

[0008] Its preparation process includes the following steps:

[0009] Step 1: The magnesite is fed into a kiln and calcined at 830-850℃ for 3-4 hours. Then, the temperature is raised to 950-960℃ and held for calcination for 2-3 hours. Finally, it is quenched and crushed into magnesite powder.

[0010] Step 2: First, feed magnesite powder, quartz sand, granite fiber, and high-alumina clay into a mixer and mix them evenly. Then, add wood cellulose, hollow glass microspheres, pigments, and dispersants and mix them evenly. Finally, add resin and curing agent and mix them evenly to obtain a premix.

[0011] Step 3: After spreading the premixed material evenly on the mold, perform vacuum vibration and vacuum degassing, then place it at a temperature of 180-190℃ for 1-2 hours to cure, then cool to room temperature and cure at room temperature for 24-48 hours to obtain the blank.

[0012] Step four: The blank is fed into a thickness calibrating device for thickness calibration; after thickness calibration is completed, it enters a polishing machine for water polishing to obtain the environmentally friendly artificial stone.

[0013] Furthermore, the production method of the granite fiber is as follows:

[0014] A. Clean the granite waste, remove the yellow skin, water rust and mud from the surface of the granite ore, and crush the cleaned granite waste to below 10 mesh;

[0015] B. Soak the crushed granite waste in foaming solution for 5-6 hours, then wash it with water to obtain granite sand particles.

[0016] C. Grind granite sand particles to below 100 mesh, mix with methyltriethoxysilane, polyvinyl alcohol, and borax, and add to a homogenization furnace for homogenization to obtain drawing raw material. Then, send the drawing raw material into a crucible and prepare granite fibers through a monofilament test bench.

[0017] Furthermore, in step C, the amount of methyltriethoxysilane added is 1-2% of the weight of the granite sand grains, the amount of polyvinyl alcohol added is 0.5-0.8% of the weight of the granite sand grains, and the amount of borax added is 0.1-0.3% of the weight of the granite sand grains.

[0018] Furthermore, in step C, the drawing temperature is 1440-1480℃, and the drawing speed is 15-21m / s.

[0019] Furthermore, in step three, the vacuum degree of the vacuum vibration is 0.08 MPa, the vibration frequency is 30 Hz, and the vibration time is 10 min.

[0020] Furthermore, the quartz sand comprises 30-40 parts of 5-10 mesh quartz sand, 25-32 parts of 30-50 mesh quartz sand, and 10-20 parts of 10-25 mesh quartz sand.

[0021] Furthermore, the dispersant is carboxymethyl cellulose.

[0022] 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:

[0023] This invention improves the strength and compressive strength of artificial quartz stone by limiting the raw material composition and using a specific preparation process. This allows the artificial quartz stone to withstand the influence of the external environment on its properties, enabling its use in high-temperature environments and broadening its application range. Specifically, the introduction of lignocellulose, mixed with other raw materials to form a three-dimensional network structure, combined with uniformly dispersed hollow glass microspheres, enhances the compressive strength of the prepared artificial quartz stone, making it less prone to cracking and breakage over long-term use. Simultaneously, the lignocellulose ensures uniform moisture distribution within the premixed material, maintaining its original shape and reducing shrinkage during curing, thereby minimizing cracking during the curing process and guaranteeing the dimensional and thermal stability of the prepared artificial quartz stone.

[0024] Introducing magnesite into the raw material composition, along with a limited pretreatment method, and combining it with other raw materials can increase the heat distortion temperature of the prepared artificial quartz stone, making it suitable for high-temperature environments. In the existing technology, pure magnesite ore is scarce and expensive, while low-quality magnesite containing dolomite and talc cannot be used directly, resulting in the waste of resources. Therefore, in the preparation process, the low-grade magnesite is pretreated first, and a two-stage calcination is used to make the treated magnesite powder contain porous pure magnesite powder that can improve thermal stability, as well as dolomite powder and talc powder that enhance strength, so as to improve the overall performance of artificial quartz stone.

[0025] Specifically, the production process of granite fiber is limited, and methyl ethoxysilane, polyvinyl alcohol and borax are added to modify the granite sand particles to improve the adhesion between the granite fiber surface and other raw materials, thereby increasing the bonding force between the granite fiber and other raw materials and ensuring the overall strength of the prepared artificial quartz stone.

[0026] Introducing high-alumina clay into the raw material composition reduces the amount of resin used while improving the heat resistance of artificial quartz stone, thereby increasing its heat distortion temperature. At the same time, combined with a limited curing process, the density of the material can be improved, ensuring the strength of the prepared artificial quartz stone. Detailed Implementation

[0027] The present invention will be further described below through specific embodiments.

[0028] An environmentally friendly artificial quartz stone comprises the following raw materials in parts by weight: 40-50 parts quartz sand, 22-28 parts magnesite, 10-12 parts granite fiber, 12-16 parts wood fiber, 8-10 parts hollow glass microspheres, 1-2 parts pigment, 8-10 parts high-alumina clay, 5-8 parts resin, 0.3-0.7 parts curing agent, and 2-3 parts carboxymethyl cellulose. The quartz sand includes 30-40 parts of 5-10 mesh quartz sand, 25-32 parts of 30-50 mesh quartz sand, and 10-20 parts of 10-25 mesh quartz sand.

[0029] Its preparation process includes the following steps:

[0030] Step 1: The magnesite is fed into a kiln and calcined at 830-850℃ for 3-4 hours. Then, the temperature is raised to 950-960℃ and held for calcination for 2-3 hours. Finally, it is quenched and crushed into magnesite powder.

[0031] Step 2: First, feed magnesite powder, quartz sand, granite fiber, and high-alumina clay into a mixer and mix them evenly. Then, add wood cellulose, hollow glass microspheres, pigment, and carboxymethyl cellulose and mix them evenly. Finally, add resin and curing agent and mix them evenly to obtain a premix.

[0032] Step 3: After spreading the premixed material evenly on the mold, perform vacuum vibration and vacuum degassing, then place it at a temperature of 180-190℃ for 1-2 hours to cure, then cool to room temperature and cure at room temperature for 24-48 hours to obtain the blank. The vacuum degree of the vacuum vibration is 0.08 MPa, the vibration frequency is 30 Hz, and the vibration time is 10 minutes.

[0033] Step four: The blank is fed into a thickness calibrating device for thickness calibration; after thickness calibration is completed, it enters a polishing machine for water polishing to obtain the environmentally friendly artificial stone.

[0034] The production method of granite fiber is as follows:

[0035] A. Clean the granite waste, remove the yellow skin, water rust and mud from the surface of the granite ore, and crush the cleaned granite waste to below 10 mesh;

[0036] B. Soak the crushed granite waste in foaming solution for 5-6 hours, then wash it with water to obtain granite sand particles.

[0037] C. Grind granite sand particles to below 100 mesh, mix with methyltriethoxysilane, polyvinyl alcohol, and borax, and add to a homogenization furnace for homogenization to obtain drawing raw material. The drawing raw material is then fed into a crucible and granite fibers are prepared through a monofilament test bench. The amount of methyltriethoxysilane added is 1-2% of the weight of granite sand particles, the amount of polyvinyl alcohol added is 0.5-0.8% of the weight of granite sand particles, and the amount of borax added is 0.1-0.3% of the weight of granite sand particles. The drawing temperature is 1440-1480℃, and the drawing speed is 15-21m / s.

[0038] Example 1

[0039] An environmentally friendly artificial quartz stone comprises the following raw materials in parts by weight: 40 parts quartz sand, 28 parts magnesite, 10 parts granite fiber, 16 parts wood fiber, 10 parts hollow glass microspheres, 1 part pigment, 10 parts high-alumina clay, 5 parts resin, 0.7 parts curing agent, and 2 parts carboxymethyl cellulose. The quartz sand comprises 30 parts 5-10 mesh quartz sand, 32 parts 30-50 mesh quartz sand, and 20 parts 10-25 mesh quartz sand.

[0040] Its preparation process includes the following steps:

[0041] Step 1: The magnesite is fed into a kiln and calcined at 830℃ for 4 hours. Then, the temperature is raised to 950℃ and held for calcination for 3 hours. Finally, it is quenched and crushed into magnesite powder.

[0042] Step 2: First, feed magnesite powder, quartz sand, granite fiber, and high-alumina clay into a mixer and mix them evenly. Then, add wood cellulose, hollow glass microspheres, pigment, and carboxymethyl cellulose and mix them evenly. Finally, add resin and curing agent and mix them evenly to obtain a premix.

[0043] Step 3: After spreading the premixed material evenly on the mold, vacuum vibration and vacuum degassing are performed. Then, the material is placed at 190°C and cured for 1 hour. After cooling to room temperature, it is cured at room temperature for 24 hours to obtain the blank. The vacuum degree of the vacuum vibration is 0.08 MPa, the vibration frequency is 30 Hz, and the vibration time is 10 minutes.

[0044] Step four: The blank is fed into a thickness calibrating device for thickness calibration; after thickness calibration is completed, it enters a polishing machine for water polishing to obtain the environmentally friendly artificial stone.

[0045] The production method of granite fiber is as follows:

[0046] A. Clean the granite waste, remove the yellow skin, water rust and mud from the surface of the granite ore, and crush the cleaned granite waste to below 10 mesh;

[0047] B. Soak the crushed granite waste in foaming solution for 5 hours, then wash it with water to obtain granite sand particles.

[0048] C. Grind granite sand particles to below 100 mesh, mix with methyltriethoxysilane, polyvinyl alcohol, and borax, and add to a homogenization furnace for homogenization to obtain drawing raw material. The drawing raw material is then fed into a crucible and granite fibers are prepared through a monofilament test bench. The amount of methyltriethoxysilane added is 2% of the weight of granite sand particles, the amount of polyvinyl alcohol added is 0.5-0.8% of the weight of granite sand particles, and the amount of borax added is 0.3% of the weight of granite sand particles. The drawing temperature is 1440℃, and the drawing speed is 15m / s.

[0049] Example 2

[0050] An environmentally friendly artificial quartz stone comprises the following raw materials in parts by weight: 50 parts quartz sand, 22 parts magnesite, 12 parts granite fiber, 12 parts wood fiber, 8 parts hollow glass microspheres, 2 parts pigment, 8 parts high-alumina clay, 8 parts resin, 0.3 parts curing agent, and 3 parts carboxymethyl cellulose. The quartz sand includes 40 parts of 5-10 mesh quartz sand, 25 parts of 30-50 mesh quartz sand, and 10 parts of 10-25 mesh quartz sand.

[0051] Its preparation process includes the following steps:

[0052] Step 1: The magnesite is fed into a kiln and calcined at 850℃ for 3 hours. Then, the temperature is raised to 960℃ and held for calcination for 2 hours. Finally, it is quenched and crushed into magnesite powder.

[0053] Step 2: First, feed magnesite powder, quartz sand, granite fiber, and high-alumina clay into a mixer and mix them evenly. Then, add wood cellulose, hollow glass microspheres, pigment, and carboxymethyl cellulose and mix them evenly. Finally, add resin and curing agent and mix them evenly to obtain a premix.

[0054] Step 3: After spreading the premixed material evenly on the mold, vacuum vibration and vacuum degassing are performed. Then, the material is placed at 180°C and cured for 2 hours. After cooling to room temperature, it is cured at room temperature for 48 hours to obtain the blank. The vacuum degree of the vacuum vibration is 0.08 MPa, the vibration frequency is 30 Hz, and the vibration time is 10 minutes.

[0055] Step four: The blank is fed into a thickness calibrating device for thickness calibration; after thickness calibration is completed, it enters a polishing machine for water polishing to obtain the environmentally friendly artificial stone.

[0056] The production method of granite fiber is as follows:

[0057] A. Clean the granite waste, remove the yellow skin, water rust and mud from the surface of the granite ore, and crush the cleaned granite waste to below 10 mesh;

[0058] B. Soak the crushed granite waste in foaming solution for 6 hours, then wash it with water to obtain granite sand particles.

[0059] C. Grind granite sand particles to below 100 mesh, mix with methyltriethoxysilane, polyvinyl alcohol, and borax, and add to a homogenization furnace for homogenization to obtain drawing raw material. The drawing raw material is then fed into a crucible and granite fibers are prepared through a monofilament test bench. The amount of methyltriethoxysilane added is 1% of the weight of granite sand particles, the amount of polyvinyl alcohol added is 0.8% of the weight of granite sand particles, and the amount of borax added is 0.1% of the weight of granite sand particles. The drawing temperature is 1480℃ and the drawing speed is 21m / s.

[0060] Example 3

[0061] An environmentally friendly artificial quartz stone comprises the following raw materials in parts by weight: 45 parts quartz sand, 25 parts magnesite, 11 parts granite fiber, 14 parts wood fiber, 9 parts hollow glass microspheres, 1.5 parts pigment, 9 parts high-alumina clay, 6 parts resin, 0.5 parts curing agent, and 2.5 parts carboxymethyl cellulose. The quartz sand includes 35 parts of 5-10 mesh quartz sand, 28 parts of 30-50 mesh quartz sand, and 15 parts of 10-25 mesh quartz sand.

[0062] Its preparation process includes the following steps:

[0063] Step 1: The magnesite is fed into a kiln and calcined at 840℃ for 3.5 hours. Then, it is heated to 955℃ and held for calcination for 2.5 hours. Finally, it is quenched and crushed into magnesite powder.

[0064] Step 2: First, feed magnesite powder, quartz sand, granite fiber, and high-alumina clay into a mixer and mix them evenly. Then, add wood cellulose, hollow glass microspheres, pigment, and carboxymethyl cellulose and mix them evenly. Finally, add resin and curing agent and mix them evenly to obtain a premix.

[0065] Step 3: After spreading the premixed material evenly on the mold, vacuum vibration and vacuum degassing are performed. Then, the material is placed at 185℃ and cured for 1.5 hours. After cooling to room temperature, it is cured at room temperature for 32 hours to obtain the blank. The vacuum degree of the vacuum vibration is 0.08 MPa, the vibration frequency is 30 Hz, and the vibration time is 10 minutes.

[0066] Step four: The blank is fed into a thickness calibrating device for thickness calibration; after thickness calibration is completed, it enters a polishing machine for water polishing to obtain the environmentally friendly artificial stone.

[0067] The production method of granite fiber is as follows:

[0068] A. Clean the granite waste, remove the yellow skin, water rust and mud from the surface of the granite ore, and crush the cleaned granite waste to below 10 mesh;

[0069] B. Soak the crushed granite waste in foaming solution for 5.5 hours, then wash it with water to obtain granite sand particles.

[0070] C. Grind granite sand particles to below 100 mesh, mix with methyltriethoxysilane, polyvinyl alcohol, and borax, and add to a homogenization furnace for homogenization to obtain drawing raw material. The drawing raw material is then fed into a crucible and granite fibers are prepared through a monofilament test bench. The amount of methyltriethoxysilane added is 1.5% of the weight of granite sand particles, the amount of polyvinyl alcohol added is 0.6% of the weight of granite sand particles, and the amount of borax added is 0.2% of the weight of granite sand particles. The drawing temperature is 1460℃, and the drawing speed is 18m / s.

[0071] Comparative Example 1

[0072] It is commercially available artificial quartz stone.

[0073] Comparative Example 2

[0074] Its raw material composition and preparation method are basically the same as those in Example 3. The difference is that magnesite is directly mixed with other raw materials without undergoing two-stage calcination pretreatment.

[0075] The artificial quartz stones obtained in Examples 1-3 and Comparative Examples 1-2 were tested, and the following data were obtained:

[0076] Table 1 Test Data for Each Embodiment

[0077] project Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 Tensile strength / MPa 80 82 85 65 72 Compressive strength / MPa 248 250 255 180 232 Mohs hardness 7.0 7.0 7.2 5.5 6.4 Heat distortion temperature / ℃ 76 75 80 60 62

[0078] As shown in the table above, the artificial quartz stone prepared by this invention has high strength and compressive strength, as well as a high heat distortion temperature. It can withstand the influence of the external environment on the stone's performance and can be used in high-temperature environments, thus broadening the application range of artificial quartz stone. In particular, the introduction of magnesite into the raw material composition, combined with a limited pretreatment method and other raw materials, can improve the heat distortion temperature of the prepared artificial quartz stone, making it suitable for high-temperature environments. Furthermore, as can be seen from the comparison between Example 3 and Comparative Example 2, the two-stage calcination process results in the treated magnesite powder containing porous pure magnesite powder that improves thermal stability, as well as dolomite powder and talc powder that enhance strength, thereby improving the overall performance of the artificial quartz stone.

[0079] 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. An environmentally friendly artificial quartz stone preparation process, characterized in that: The environmentally friendly artificial stone comprises the following raw materials in parts by weight: 40-50 parts quartz sand, 22-28 parts magnesite, 10-12 parts granite fiber, 12-16 parts wood fiber, 8-10 parts hollow glass microspheres, 1-2 parts pigment, 8-10 parts high-alumina clay, 5-8 parts resin, 0.3-0.7 parts curing agent, and 2-3 parts dispersant; Its preparation process includes the following steps: Step 1: The magnesite is fed into a kiln and calcined at 830-850℃ for 3-4 hours. Then, the temperature is raised to 950-960℃ and held for calcination for 2-3 hours. Finally, it is quenched and crushed into magnesite powder. Step 2: First, feed magnesite powder, quartz sand, granite fiber, and high-alumina clay into a mixer and mix them evenly. Then, add wood cellulose, hollow glass microspheres, pigments, and dispersants and mix them evenly. Finally, add resin and curing agent and mix them evenly to obtain a premix. Step 3: After spreading the premixed material evenly on the mold, perform vacuum vibration and vacuum degassing, then place it at a temperature of 180-190℃ for 1-2 hours to cure, then cool to room temperature and cure at room temperature for 24-48 hours to obtain the blank. Step four: The blank is fed into a thickness calibrating device for thickness calibration; after thickness calibration is completed, it enters a polishing machine for water polishing to obtain the environmentally friendly artificial stone.

2. The environmentally friendly artificial quartz stone preparation process according to claim 1, characterized in that: The production method of the granite fiber is as follows: A. Clean the granite waste, remove the yellow skin, water rust and mud from the surface of the granite ore, and crush the cleaned granite waste to below 10 mesh; B. Soak the crushed granite waste in foaming solution for 5-6 hours, then wash it with water to obtain granite sand particles. C. Grind granite sand particles to below 100 mesh, mix with methyltriethoxysilane, polyvinyl alcohol, and borax, and add to a homogenization furnace for homogenization to obtain drawing raw material. Then, send the drawing raw material into a crucible and prepare granite fibers through a monofilament test bench.

3. The environmentally friendly artificial quartz stone preparation process according to claim 2, characterized in that: In step C, the amount of methyltriethoxysilane added is 1-2% of the weight of the granite sand grains, the amount of polyvinyl alcohol added is 0.5-0.8% of the weight of the granite sand grains, and the amount of borax added is 0.1-0.3% of the weight of the granite sand grains.

4. The environmentally friendly artificial quartz stone preparation process according to claim 2, characterized in that: In step C, the drawing temperature is 1440-1480℃ and the drawing speed is 15-21m / s.

5. The environmentally friendly artificial quartz stone preparation process according to claim 1, characterized in that: In step three, the vacuum degree of the vacuum vibration is 0.08 MPa, the vibration frequency is 30 Hz, and the vibration time is 10 min.

6. The environmentally friendly artificial quartz stone preparation process according to claim 1, characterized in that: The quartz sand comprises 30-40 parts of 5-10 mesh quartz sand, 25-32 parts of 30-50 mesh quartz sand, and 10-20 parts of 10-25 mesh quartz sand.

7. The environmentally friendly artificial quartz stone preparation process according to claim 1, characterized in that: The dispersant is carboxymethyl cellulose.