Environment-friendly artificial stone production process

Abstract

The present application relates to artificial stone production technical field, disclose a kind of environment-friendly artificial stone production process, comprising the following steps: S1, material preparation;S2, mixed material: by mixing equipment, material is mixed fully;S3, pressing: even slurry is poured into the mold required for artificial stone;S4, solidification: after pressing, artificial stone mold is placed in constant temperature and humidity environment;S5, demolding: so that solidification artificial stone is released from mold;S6, cutting and finishing;The present application has been used including renewable materials such as waste artificial stone fragments, waste glass, waste ceramics, waste quartz and waste marble fragments, realizes the environmental protection concept;The present application has been used including silicone reinforcing agent, methyl silicone oil reinforcing agent, organic silicon resin reinforcing agent and silicone resin reinforcing agent in organic silicon reinforcing agent, the artificial stone produced has higher compressive strength and waterproof performance, and performance is far superior to the artificial stone produced by prior art.

Description

Technical Field

[0001] This invention relates to the field of artificial stone production technology, specifically an environmentally friendly artificial stone production process. Background Technology

[0002] Artificial stone is mainly used in the building decoration industry. It is a new type of environmentally friendly composite material. Compared with traditional building materials such as stainless steel and ceramics, artificial stone is not only more versatile and colorful, but also has a wider range of applications. With the widespread use of artificial stone, the amount of waste slabs, scraps, and especially artificial stone waste has also increased significantly.

[0003] A Chinese patent discloses a production process and formula for artificial stone (authorization announcement number CN102336535B). This patented technology utilizes existing artificial stone waste and adopts a new molding process to reuse the waste and produce a new product to meet market demand. However, it has certain drawbacks: the materials used are not particularly special, consisting of conventional matrix, additives, etc. Therefore, the strength and waterproof performance of the produced artificial stone are not improved, thus failing to extend its service life and consequently failing to reduce wear and tear and achieve the concept of environmental protection by extending its service life. Summary of the Invention

[0004] The purpose of this invention is to provide an environmentally friendly artificial stone production process to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] An environmentally friendly artificial stone production process includes the following steps:

[0007] S1. Material preparation: Prepare sand, prepolymer, renewable materials, dyes, additives and water required for the production of environmentally friendly artificial stone;

[0008] S2. Mixing materials: Put sand, prepolymer, renewable materials, dyes, additives and water into a mixing and stirring device, and mix the materials thoroughly with the stirring device until a uniform slurry is formed;

[0009] S3. Pressing: Pour the uniform slurry into the mold required for the artificial stone, and use a vibratory machine or vibratory platform to compact the slurry to remove air bubbles and ensure the density of the material;

[0010] S4. Curing: Place the pressed artificial stone mold in an environment with constant temperature and humidity and cure for a period of time;

[0011] S5. Demolding: Use a tool to gently tap the mold to help loosen the artificial stone and allow the hardened artificial stone to come out of the mold;

[0012] S6. Cutting and Finishing: Use cutting machinery to cut the artificial stone into slabs or bricks of the required size, and then finish the surface of the artificial stone.

[0013] As a further embodiment of the present invention: the mass ratio of sand, prepolymer, renewable material, dye, additive and water in S1 is 30-50:10-20:20-40:1-5:1-5:10-20.

[0014] As a further embodiment of the present invention, the prepolymer is any one of epoxy resin, polyester resin and cement.

[0015] As a further aspect of the present invention: the renewable materials include waste artificial stone fragments, waste glass, waste ceramics, waste quartz and waste marble fragments.

[0016] As a further aspect of the present invention: the dyeing agent is any one of natural inorganic pigments, plant extract dyes, and water-based dyes.

[0017] As a further embodiment of the present invention: the additive is an organosilicon reinforcing agent, which includes silicone reinforcing agent, methyl silicone oil reinforcing agent, organosilicon resin reinforcing agent and silicone resin reinforcing agent, wherein the mass ratio of silicone reinforcing agent, methyl silicone oil reinforcing agent, organosilicon resin reinforcing agent and silicone resin reinforcing agent is 1:3-5:3-5:1.

[0018] As a further embodiment of the present invention: the silicone reinforcing agent is any one of chain polymethylsiloxane, polydimethylsiloxane, and methyl silicone oil; the methyl silicone oil reinforcing agent is any one of methyl polysiloxane and methyl sulfonyl polysiloxane; the organosilicon resin reinforcing agent is any one of organosilicon acrylate resin, organosilicon resin, and organosilicon epoxy resin; and the silicone resin reinforcing agent is any one of polydimethylsiloxane resin and methylsiloxane crosslinking resin.

[0019] As a further embodiment of the present invention: the constant temperature in S4 is 20-30℃, the constant humidity is 40-70%, and the curing time is 24-48h.

[0020] As a further aspect of the present invention: the finishing of the artificial stone surface in S6 includes polishing, sanding and sandblasting.

[0021] Compared with the prior art, the beneficial effects of the present invention are:

[0022] In the production of artificial stone, this invention uses renewable materials including waste artificial stone fragments, waste glass, waste ceramics, waste quartz and waste marble fragments, realizing the reuse of waste resources and thus achieving the concept of environmental protection.

[0023] This invention uses organosilicon reinforcing agents, including silicone reinforcing agents, methyl silicone oil reinforcing agents, organosilicon resin reinforcing agents, and silicone resin reinforcing agents, as additives. The organosilicon functional groups (e.g., siloxane groups) in the organosilicon reinforcing agents can react with free calcium ions in cement or active groups (e.g., hydroxyl groups) in resins. These reactions lead to the formation of covalent bonds or physical cross-linking structures between the siloxane groups and the matrix, thereby firmly bonding the organosilicon reinforcing agent to the matrix. Due to the formation of covalent bonds or physical cross-linking structures, the bond between the organosilicon reinforcing agent and the matrix is ​​stronger and less prone to damage or decomposition, thus improving the compressive strength, flexural strength, and impact resistance of the artificial stone, making it more durable and reliable. The organosilicon functional groups (such as siloxane groups) in the artificial stone have hydrophobic properties, meaning they repel water. Furthermore, the organosilicon functional groups are inert and do not readily react with water or other solvents, allowing the artificial stone to remain stable even in humid environments. This prevents moisture from penetrating the material and reduces hydrolysis. The silicon atoms in the organosilicon reinforcing agent can form strong chemical bonds with oxygen atoms, giving it excellent oxidation resistance. Therefore, the artificial stone produced by this invention has high compressive strength and waterproof performance, far superior to artificial stone produced by existing technologies. This significantly extends the lifespan of the artificial stone, reduces wear and tear, lowers maintenance costs, and achieves environmental protection goals. Detailed Implementation

[0024] Example 1

[0025] An environmentally friendly artificial stone production process includes the following steps:

[0026] S1. Material preparation: Prepare sand, prepolymer, renewable materials, dyes, additives and water required for the production of environmentally friendly artificial stone. The mass ratio of sand, prepolymer, renewable materials, dyes, additives and water is 30:10:20:5:5:20.

[0027] S2. Mixing materials: Put sand, prepolymer, renewable materials, dyes, additives and water into a mixing and stirring device, and mix the materials thoroughly with the stirring device until a uniform slurry is formed;

[0028] S3. Pressing: Pour the uniform slurry into the mold required for the artificial stone, and use a vibratory machine or vibratory platform to compact the slurry to remove air bubbles and ensure the density of the material;

[0029] S4. Curing: Place the pressed artificial stone mold in an environment with a temperature of 20℃ and a humidity of 40% and cure for 24 hours.

[0030] S5. Demolding: Use a tool to gently tap the mold to help loosen the artificial stone and allow the hardened artificial stone to come out of the mold;

[0031] S6. Cutting and Finishing: Use cutting machinery to cut the artificial stone into slabs or bricks of the required size, and then polish, sand, and sandblast the surface of the artificial stone.

[0032] Preferably, the prepolymer is epoxy resin.

[0033] Preferably, renewable materials include waste artificial stone fragments, waste glass, waste ceramics, waste quartz, and waste marble fragments.

[0034] Preferably, the dye is a natural inorganic pigment.

[0035] Preferably, the additive is an organosilicon reinforcing agent, which includes silicone reinforcing agent, methyl silicone oil reinforcing agent, organosilicon resin reinforcing agent and silicone resin reinforcing agent, wherein the mass ratio of silicone reinforcing agent, methyl silicone oil reinforcing agent, organosilicon resin reinforcing agent and silicone resin reinforcing agent is 1:3:5:1;

[0036] The silicone reinforcing agent is a chain-like polymethylsiloxane, the methyl silicone oil reinforcing agent is a methyl polysiloxane, the organosilicon resin reinforcing agent is an organosilicon acrylate resin, and the silicone resin reinforcing agent is a polydimethylsiloxane resin.

[0037] Example 2

[0038] An environmentally friendly artificial stone production process includes the following steps:

[0039] S1. Material preparation: Prepare sand, prepolymer, renewable materials, dyes, additives and water required for the production of environmentally friendly artificial stone. The mass ratio of sand, prepolymer, renewable materials, dyes, additives and water is 37:13:26:3.5:3.5:17.

[0040] S2. Mixing materials: Put sand, prepolymer, renewable materials, dyes, additives and water into a mixing and stirring device, and mix the materials thoroughly with the stirring device until a uniform slurry is formed;

[0041] S3. Pressing: Pour the uniform slurry into the mold required for the artificial stone, and use a vibratory machine or vibratory platform to compact the slurry to remove air bubbles and ensure the density of the material;

[0042] S4. Curing: Place the pressed artificial stone mold in an environment with a temperature of 23℃ and a humidity of 50% for 32 hours to cure.

[0043] S5. Demolding: Use a tool to gently tap the mold to help loosen the artificial stone and allow the hardened artificial stone to come out of the mold;

[0044] S6. Cutting and Finishing: Use cutting machinery to cut the artificial stone into slabs or bricks of the required size, and then polish, sand, and sandblast the surface of the artificial stone.

[0045] Preferably, the prepolymer is a polyester resin.

[0046] Preferably, renewable materials include waste artificial stone fragments, waste glass, waste ceramics, waste quartz, and waste marble fragments.

[0047] Preferably, the dye is a plant extract dye.

[0048] Preferably, the additive is an organosilicon reinforcing agent, which includes silicone reinforcing agent, methyl silicone oil reinforcing agent, organosilicon resin reinforcing agent and silicone resin reinforcing agent, wherein the mass ratio of silicone reinforcing agent, methyl silicone oil reinforcing agent, organosilicon resin reinforcing agent and silicone resin reinforcing agent is 1:3.7:4.3:1;

[0049] The silicone reinforcing agent is polydimethylsiloxane, the methyl silicone oil reinforcing agent is methyl sulfonyl polysiloxane, the organosilicon resin reinforcing agent is organosilicon epoxy resin, and the silicone resin reinforcing agent is methylsiloxane crosslinked resin.

[0050] Example 3

[0051] An environmentally friendly artificial stone production process includes the following steps:

[0052] S1. Material preparation: Prepare sand, prepolymer, renewable materials, dyes, additives and water required for the production of environmentally friendly artificial stone. The mass ratio of sand, prepolymer, renewable materials, dyes, additives and water is 43:16:33:2:2:13.

[0053] S2. Mixing materials: Put sand, prepolymer, renewable materials, dyes, additives and water into a mixing and stirring device, and mix the materials thoroughly with the stirring device until a uniform slurry is formed;

[0054] S3. Pressing: Pour the uniform slurry into the mold required for the artificial stone, and use a vibratory machine or vibratory platform to compact the slurry to remove air bubbles and ensure the density of the material;

[0055] S4. Curing: Place the pressed artificial stone mold in an environment with a temperature of 26℃ and a humidity of 60% for 40 hours to cure.

[0056] S5. Demolding: Use a tool to gently tap the mold to help loosen the artificial stone and allow the hardened artificial stone to come out of the mold;

[0057] S6. Cutting and Finishing: Use cutting machinery to cut the artificial stone into slabs or bricks of the required size, and then polish, sand, and sandblast the surface of the artificial stone.

[0058] Preferably, the prepolymer is cement.

[0059] Preferably, renewable materials include waste artificial stone fragments, waste glass, waste ceramics, waste quartz, and waste marble fragments.

[0060] Preferably, the dye is an aqueous dye.

[0061] Preferably, the additive is an organosilicon reinforcing agent, which includes silicone reinforcing agent, methyl silicone oil reinforcing agent, organosilicon resin reinforcing agent and silicone resin reinforcing agent, wherein the mass ratio of silicone reinforcing agent, methyl silicone oil reinforcing agent, organosilicon resin reinforcing agent and silicone resin reinforcing agent is 1:4.3:3.7:1;

[0062] The silicone reinforcing agent is methyl silicone oil, the methyl silicone oil reinforcing agent is methyl polysiloxane, the organosilicon resin reinforcing agent is organosilicon epoxy resin, and the silicone resin reinforcing agent is polydimethylsiloxane resin.

[0063] Example 4

[0064] An environmentally friendly artificial stone production process includes the following steps:

[0065] S1. Material preparation: Prepare sand, prepolymer, renewable materials, dyes, additives and water required for the production of environmentally friendly artificial stone. The mass ratio of sand, prepolymer, renewable materials, dyes, additives and water is 50:20:40:1:1:10.

[0066] S2. Mixing materials: Put sand, prepolymer, renewable materials, dyes, additives and water into a mixing and stirring device, and mix the materials thoroughly with the stirring device until a uniform slurry is formed;

[0067] S3. Pressing: Pour the uniform slurry into the mold required for the artificial stone, and use a vibratory machine or vibratory platform to compact the slurry to remove air bubbles and ensure the density of the material;

[0068] S4. Curing: Place the pressed artificial stone mold in an environment with a temperature of 30℃ and a humidity of 70% for 48 hours to cure.

[0069] S5. Demolding: Use a tool to gently tap the mold to help loosen the artificial stone and allow the hardened artificial stone to come out of the mold;

[0070] S6. Cutting and Finishing: Use cutting machinery to cut the artificial stone into slabs or bricks of the required size, and then polish, sand, and sandblast the surface of the artificial stone.

[0071] Preferably, the prepolymer is epoxy resin.

[0072] Preferably, renewable materials include waste artificial stone fragments, waste glass, waste ceramics, waste quartz, and waste marble fragments.

[0073] Preferably, the dye is a plant extract dye.

[0074] Preferably, the additive is an organosilicon reinforcing agent, which includes silicone reinforcing agent, methyl silicone oil reinforcing agent, organosilicon resin reinforcing agent and silicone resin reinforcing agent, wherein the mass ratio of silicone reinforcing agent, methyl silicone oil reinforcing agent, organosilicon resin reinforcing agent and silicone resin reinforcing agent is 1:5:3:1;

[0075] The silicone reinforcing agent is polydimethylsiloxane, the methyl silicone oil reinforcing agent is methyl sulfonyl polysiloxane, the organosilicon resin reinforcing agent is organosilicon epoxy resin, and the silicone resin reinforcing agent is methylsiloxane crosslinked resin.

[0076] To further illustrate the technical effects of the present invention, the following experiments were conducted for verification:

[0077] The artificial stones produced in Examples 1 to 4 of the present invention are designated as Experimental Examples A, B, C, and D;

[0078] The artificial stone produced using the production process and formula for artificial stone disclosed in Chinese Patent (Authorization Announcement No. CN102336535B) is Comparative Example E;

[0079] Two pieces were taken from each experimental example and comparative example, and they were exactly the same size and shape;

[0080] Experiment 1

[0081] Take a sample from the experimental example and a comparative example respectively, weigh them, and then place the sample from the experimental example and the comparative example in a container. Slowly pour pure water into the container until the sample is completely immersed in it, keeping the height difference between the upper surface of the sample and the water surface 20 mm.

[0082] At (1±0.25) h, (8±0.5) h, and (24±1) h after the start of the experiment, the samples were removed, the surface water was wiped off with a wrung-out damp towel, and the samples were weighed quickly. The samples were then continued to be soaked in pure water, and weighed every (24±1) h until the mass change from the three weighings was within 0.1%. The final weighing was then taken as the saturated mass. The mass was then determined according to the formula...

[0083]

[0084] Experiment 2

[0085] Take the remaining specimens from both the experimental and comparative examples. Clean the stress-bearing surfaces of the specimens and the surfaces of the upper and lower indenters of the testing machine. Then, place the specimens in the center of the testing machine's worktable and adjust the surfaces of the upper and lower indenters to ensure uniform contact with the stress-bearing surfaces of the specimens. Continuously apply a load to the specimens at a uniform rate of (1±0.5) MPa / s until complete failure. Record the load at which the specimens fail, and calculate the load according to the formula... The compressive strength is obtained.

[0086] The water absorption rate and compressive strength obtained from Experiment 1 and Experiment 2 are statistically analyzed and compiled into the following table;

[0087] Comparative Example E 4.65 38.51 Experimental Example A 2.15 75.63 Experimental Example B 2.07 80.20 Experimental Example C 2.11 81.97 Experimental Example D 2.09 78.85

[0088] From the table above, we can see that the water absorption rate of experimental examples A, B, C, and D is much lower than that of comparative example E, about 1 / 2 of that of comparative example E. The compressive strength of experimental examples A, B, C, and D is much higher than that of comparative example E, about twice that of comparative example E.

[0089] Therefore, it can be concluded that the artificial stone produced by this invention has extremely high waterproof performance and compressive strength, and is far superior to artificial stone produced by existing technologies.

[0090] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

[0091] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. An environmentally friendly artificial stone production process, characterized in that, Includes the following steps: S1. Material preparation: Prepare sand, prepolymer, renewable materials, dyes, additives and water required for the production of environmentally friendly artificial stone; S2. Mixing materials: Put sand, prepolymer, renewable materials, dyes, additives and water into a mixing and stirring device, and mix the materials thoroughly with the stirring device until a uniform slurry is formed; S3. Pressing: Pour the uniform slurry into the mold required for the artificial stone, and use a vibratory machine or vibratory platform to compact the slurry to remove air bubbles and ensure the density of the material; S4. Curing: Place the pressed artificial stone mold in an environment with constant temperature and humidity and cure for a period of time; S5. Demolding: Use a tool to gently tap the mold to help loosen the artificial stone and allow the hardened artificial stone to come out of the mold; S6. Cutting and finishing: Use cutting machinery to cut the artificial stone into slabs or bricks of the required size, and then finish the surface of the artificial stone. The mass ratio of sand, prepolymer, renewable material, dye, additive and water in S1 is 30-50:10-20:20-40:1-5:1-5:10-20; The additive is an organosilicon reinforcing agent, which includes silicone reinforcing agent, methyl silicone oil reinforcing agent, organosilicon resin reinforcing agent and silicone resin reinforcing agent, wherein the mass ratio of silicone reinforcing agent, methyl silicone oil reinforcing agent, organosilicon resin reinforcing agent and silicone resin reinforcing agent is 1:3-5:3-5:1; The silicone reinforcing agent is any one of chain polymethylsiloxane, polydimethylsiloxane, and methyl silicone oil; the methyl silicone oil reinforcing agent is any one of methyl polysiloxane and methyl sulfonyl polysiloxane; the organosilicon resin reinforcing agent is any one of organosilicon acrylate resin, organosilicon resin, and organosilicon epoxy resin; and the silicone resin reinforcing agent is any one of polydimethylsiloxane resin and methylsiloxane crosslinking resin.

2. The environmentally friendly artificial stone production process according to claim 1, characterized in that, The prepolymer is any one of epoxy resin, polyester resin, and cement.

3. The environmentally friendly artificial stone production process according to claim 1, characterized in that, The renewable materials include waste artificial stone fragments, waste glass, waste ceramics, waste quartz, and waste marble fragments.

4. The environmentally friendly artificial stone production process according to claim 1, characterized in that, The dyeing agent is any one of natural inorganic pigments, plant extract dyes, and water-based dyes.

5. The environmentally friendly artificial stone production process according to claim 1, characterized in that, The constant temperature in S4 is 20-30℃, the constant humidity is 40-70%, and the curing time is 24-48h.

6. The environmentally friendly artificial stone production process according to claim 1, characterized in that, The finishing of the artificial stone surface in S6 includes polishing, sanding, and sandblasting.

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