A prefabricated composite rock panel and its preparation method

Abstract

This invention discloses a method for preparing a prefabricated composite rock slab, comprising the following steps: S1. Coating the bottom of the rock slab with fluoride and acid to form micropores; S2. Heating the rock slab obtained in S1; S3. Under heating conditions, coating the bottom of the rock slab obtained in S2 with an adhesive to allow the adhesive to penetrate into the micropores; S4. Bonding the rock slab obtained in S3 to a substrate to obtain a composite rock slab; wherein the fluoride and the acid are coated sequentially on the bottom of the rock slab. This invention also discloses a prefabricated composite rock slab. Implementing the prefabricated composite rock slab preparation method of this invention allows the rock slab to be bonded to various substrates with good bonding effect and simple process, and the resulting composite rock slab has good mechanical properties.

Description

Technical Field

[0001] This invention relates to the field of slab processing technology, and in particular to an assembled composite slab and its preparation method. Background Technology

[0002] Sintered stone slabs are a new type of ceramic material made by vacuum extruding and firing natural materials such as stone powder and inorganic clay. They possess significant advantages such as fire resistance, high-temperature resistance, stain resistance, scratch resistance, corrosion resistance, easy cleaning, and safety and hygiene, making them a highly sought-after high-end building material in the market. However, sintered stone slabs still suffer from problems such as easy breakage and damage during the processing and transportation of customized home furnishings. Furthermore, with evolving consumer demands, single-material slabs cannot meet current performance requirements, making composite slabs that satisfy both design and performance a new research trend.

[0003] Currently, the adhesive materials used in composite slabs need to be selected based on the material of the substrate, increasing the processing difficulty and cost. Chinese patent application CN116080169A discloses a prefabricated slab and its preparation method. This method involves sandblasting the back of the slab, applying an adhesive, bonding it to the substrate, and finally obtaining the initial product through localized top pressing and overall static pressing. This allows the slab to effectively bond to various substrates, such as slabs combined with bamboo charcoal fiber boards, cement fiber boards, honeycomb boards, calcium silicate boards, foamed ceramic boards, or metal boards, with good adhesion performance. However, this technical solution requires multiple sandblasting treatments on the back of the slab using sand of different particle sizes to achieve a specific roughness, allowing for better interaction with the adhesive and improving adhesion performance. The process is complex, and the adhesion performance still needs further improvement.

[0004] It is evident that existing technologies cannot simultaneously achieve the technical effects of using the same adhesive material to composite rock slabs with different substrate boards, while also ensuring simple processing and good adhesion. Based on the aforementioned patents, the applicant has conducted further research. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a prefabricated composite slab and its preparation method, which enables the slab to be bonded to a variety of substrates, and the preparation method is simple and the bonding effect is good, thereby further expanding the application scenarios of the slab.

[0006] To address the aforementioned technical problems, the first aspect of this invention provides a method for preparing prefabricated composite rock panels, comprising the following steps:

[0007] S1. Fluoride and acid are coated onto the bottom of the rock slab to form micropores;

[0008] S2. Heat-treat the rock slab obtained in S1;

[0009] S3. Under heating conditions, apply an adhesive to the bottom of the rock slab obtained in S2 to allow the adhesive to penetrate into the micropores;

[0010] S4. Bond the slab obtained in S3 to the substrate board to obtain a composite slab;

[0011] The fluoride and the acid are applied sequentially to the bottom of the rock slab.

[0012] As an improvement to the above scheme, when the fluoride and the acid are successively coated on the bottom of the rock slab, a mixing tool is used to mix them evenly on the bottom of the rock slab to allow them to react.

[0013] Furthermore, the mixing tool includes, but is not limited to, a brush, a sponge, and a scraper.

[0014] As an improvement to the above scheme, S1 includes: first coating the bottom of the rock slab with fluoride, then coating it with acid, and mixing the two evenly during the coating process, wherein the fluoride is added in the form of an aqueous fluoride solution.

[0015] Furthermore, during the coating process, the acid and the fluoride aqueous solution can be mixed evenly with a brush to ensure a complete reaction.

[0016] As an improvement to the above scheme, in S1, the fluoride is one or more of sodium fluoride, ammonium fluoride, and potassium fluoride; more preferably, sodium fluoride, ammonium fluoride, and potassium fluoride.

[0017] As an improvement to the above scheme, the aqueous fluoride solution comprises, by weight: 40-65 parts sodium fluoride, 10-40 parts ammonium fluoride, 5-25 parts potassium fluoride, and 100 parts purified water.

[0018] Further, by weight, the fluoride aqueous solution comprises: 45-60 parts sodium fluoride, 15-35 parts ammonium fluoride, 10-20 parts potassium fluoride, and 100 parts purified water.

[0019] Furthermore, by weight, the fluoride aqueous solution comprises: 50-55 parts sodium fluoride, 20-30 parts ammonium fluoride, 10-15 parts potassium fluoride, and 100 parts purified water.

[0020] As an improvement to the above scheme, the acid is one or more of hydrochloric acid, nitric acid, oxalic acid, sulfuric acid, phosphoric acid, and acetic acid; more preferably, hydrochloric acid, nitric acid, oxalic acid, and sulfuric acid.

[0021] As an improvement to the above scheme, the acids, by weight, include: 15-35 parts hydrochloric acid, 20-45 parts nitric acid, 30-55 parts oxalic acid, and 5-25 parts sulfuric acid.

[0022] Further, by weight, the acids include: 18-30 parts hydrochloric acid, 25-40 parts nitric acid, 35-50 parts oxalic acid, and 10-20 parts sulfuric acid.

[0023] Furthermore, by weight, the acids comprise: 20-25 parts hydrochloric acid, 30-35 parts nitric acid, 40-45 parts oxalic acid, and 10-15 parts sulfuric acid.

[0024] As an improvement to the above scheme, the ratio of the fluoride aqueous solution to the acid is 1:(0.6-1.6), and exemplary ratios are 1:0.6, 1:0.7, 1:0.8, 1:0.9, 1:1.0, 1:1.1, 1:1.2, 1:1.3, 1:1.4, 1:1.5, 1:1.6, or any of the above values.

[0025] Further, the ratio of the aqueous fluoride solution to the acid is 1:(0.7-1.3); more preferably 1:(0.8-1.25).

[0026] It is worth mentioning that the use of hydrofluoric acid to treat the rock slab and form micropores is also part of the technical concept of this application.

[0027] As an improvement to the above solution, the coating methods for the fluoride aqueous solution, the acid, and the adhesive include, but are not limited to, roller coating, spraying, and brush coating.

[0028] Furthermore, in S1, the coating method of the fluoride aqueous solution is roller coating, and the coating method of the acid is spray coating; in S3, the coating method of the adhesive is roller coating.

[0029] According to some specific and preferred embodiments, the amount of the fluoride aqueous solution used is 7-11 g / m², exemplarily 7 g / m², 7.5 g / m², 8 g / m², 8.5 g / m², 9 g / m², 9.5 g / m², 10 g / m², 10.5 g / m², 11 g / m², or any range of the above values.

[0030] Furthermore, the amount of the fluoride aqueous solution used is 8-10 grams per square meter.

[0031] As an improvement to the above scheme, in S1, the linear speed of the transmission belt used to transport the rock slab when coating the fluoride aqueous solution is V1, where V1 = 4-7 m / min, exemplarily 4 m / min, 4.5 m / min, 5 m / min, 5.5 m / min, 6 m / min, 6.5 m / min, 7 m / min, or any of the above values.

[0032] Furthermore, V1 = 5-6 m / min.

[0033] As an improvement to the above scheme, the amount of acid used is 7-11 grams per square meter, for example 7 grams per square meter, 7.5 grams per square meter, 8 grams per square meter, 8.5 grams per square meter, 9 grams per square meter, 9.5 grams per square meter, 10 grams per square meter, 10.5 grams per square meter, 11 grams per square meter, or any of the above values.

[0034] Furthermore, the amount of acid used is 8-10 grams per square meter.

[0035] As an improvement to the above scheme, the linear speed of the transmission belt used to transport the rock slab when coating the acid is V2, where V2 = 4-7 m / min, exemplarily 4 m / min, 4.5 m / min, 5 m / min, 5.5 m / min, 6 m / min, 6.5 m / min, 7 m / min, or any of the above values.

[0036] Furthermore, V2 = 5-6 m / min.

[0037] As an improvement to the above solution, in S1, the rock slab is a rock slab whose bottom has undergone physical cleaning treatment.

[0038] Furthermore, the physical cleaning can be carried out by using cleaning tools such as steel wool, brushes, cotton cloths, and scouring pads to clean the back of the rock slab in order to remove the aluminum oxide or magnesium oxide film on the back surface.

[0039] As an improvement to the above scheme, in step S2, the temperature of the rock slab after heat treatment is controlled to be 35-48℃; more preferably 40-45℃.

[0040] As an improvement to the above scheme, in step S2, the heat treatment is further followed by a water washing process to rinse the surface of the rock slab with flowing water to remove any remaining reactants.

[0041] As an improvement to the above solution, in S3, the heating conditions include: first heating the rock slab to 50-85°C, then applying an adhesive to the bottom of the rock slab; continuing to heat the rock slab until its temperature reaches 70-95°C.

[0042] Furthermore, the heating conditions include: first heating the rock slab to 50-75°C, then applying an adhesive to the bottom of the rock slab; continuing to heat the rock slab until its temperature reaches 70-85°C.

[0043] Furthermore, the heating conditions include: first heating the rock slab to 50-70°C, then applying an adhesive to the bottom of the rock slab; continuing to heat the rock slab until its temperature reaches 70-75°C.

[0044] As an improvement to the above scheme, in both S2 and S3, the rock slab can be placed on a transmission belt and kept moving at a certain linear speed to promote the full progress of each reaction step. The specific linear speed of the transmission belt in S2 and S3 can be randomly adjusted according to the reaction conditions.

[0045] Further, in S2, the linear speed of the transmission belt used to transport the rock slab during the heat treatment is V3; in S3, the linear speed of the transmission belt used to transport the rock slab during the application of the adhesive is V4; wherein, V3 < V1 or V2, and V3 > V4.

[0046] In some specific and preferred embodiments, V3 = 2.5-5 m / min, exemplarily 2.5 m / min, 3 m / min, 3.5 m / min, 4 m / min, 4.5 m / min, 5 m / min, or any range of the above values; more preferably V3 = 3-4.5 m / min; even more preferably V3 = 3-4 m / min.

[0047] In some specific and preferred embodiments, in step S3, the adhesive is applied by roller coating, with V4 = 0.5-3 m / min, exemplarily 0.5 m / min, 1 m / min, 1.5 m / min, 2 m / min, 2.5 m / min, 3 m / min, or any range of the above values; more preferably, V4 = 1-2.5 m / min; even more preferably, V4 = 1-2 m / min.

[0048] As an improvement to the above scheme, in S3, after applying the adhesive, the linear speed of the transmission belt used to transport the rock slab is controlled to be equal to V4.

[0049] As an improvement to the above solution, in step S3, the adhesive is a polyurethane hot melt adhesive; more preferably, it is a PUR hot melt adhesive.

[0050] As an improvement to the above solution, in step S3, the coating thickness of the adhesive is 0.3-0.7 mm, for example 0.3 mm, 0.35 mm, 0.4 mm, 0.45 mm, 0.5 mm, 0.55 mm, 0.6 mm, 0.65 mm, 0.7 mm, or any of the above values.

[0051] Furthermore, the coating thickness of the adhesive is 0.4-0.6 mm; more preferably 0.4-0.5 mm.

[0052] As an improvement to the above solution, the adhesive is subjected to a high-temperature hot-melt treatment at 110-130°C before coating; more preferably, it is 115-120°C.

[0053] As an improvement to the above scheme, in step S4, bonding the rock slab obtained in step S3 to the substrate slab also includes laser positioning, mechanical clamping, and roll pressing.

[0054] Furthermore, during the laser positioning, the deviation between the rock slab and the substrate slab in the longitudinal and / or transverse directions is < ±0.7 mm; more preferably < ±0.5 mm.

[0055] Furthermore, during the rolling process, the distance between the upper and lower rollers of the rolling process is controlled to differ from the thickness of the composite rock slab by 2.5-5 mm; more preferably 3-4.5 mm; and even more preferably 3-4 mm.

[0056] In this invention, after the adhesive is hot-melted at high temperature is rolled onto the bottom of the rock slab, laser positioning is used to bond the bottom of the rock slab to the substrate, and the rock slab and the substrate are composited by mechanical clamping. Finally, the rock slab and the substrate are pressed together by a roll pressing process to obtain a composite rock slab.

[0057] As an improvement to the above solution, in step S4, the substrate board is one or a combination of calcium silicate board, bamboo charcoal board, and stainless steel.

[0058] As an improvement to the above solution, due to the influence of adhesive performance, in order to improve the performance of the composite pressure plate, the composite rock plate can be left to stand, cool and solidify before processing.

[0059] A second aspect of the present invention also provides a prefabricated composite rock panel prepared by the method described above.

[0060] Implementing this invention has the following beneficial effects:

[0061] In this invention, the bottom of the slab is treated with fluoride and acid, followed by heat treatment. Finally, the slab is bonded to a substrate using an adhesive, resulting in a prefabricated composite slab. This preparation method allows the slab to be combined with various substrates with different properties, further expanding its application scenarios. Furthermore, the preparation method is simple, and the resulting composite material exhibits excellent adhesion and mechanical properties, is not easily separated or detached, and has good safety performance.

[0062] Furthermore, the prefabricated composite rock panels prepared by the above-described simple process can be widely used in walls, floors, doors, cabinets, ceilings, dining tables, and other applications. Attached Figure Description

[0063] Figure 1 This is a schematic diagram of the micropores in the prefabricated composite rock panel of the present invention. Detailed Implementation

[0064] To make the objectives, technical solutions, and advantages of the present invention clearer, specific embodiments will be described in further detail below.

[0065] This invention provides a method for preparing prefabricated composite rock panels, comprising the following steps:

[0066] S1. Fluoride and acid are coated onto the bottom of the rock slab to form micropores;

[0067] S2. Heat-treat the rock slab obtained in S1;

[0068] S3. Under heating conditions, apply an adhesive to the bottom of the rock slab obtained in S2 to allow the adhesive to penetrate into the micropores;

[0069] S4. Bond the slab obtained in S3 to the substrate board to obtain a composite slab;

[0070] Fluoride and acid were applied sequentially to the bottom of the rock slab.

[0071] In this invention, fluoride and acid are used to treat the bottom of the slab. Specifically, fluoride and acid are applied sequentially to the bottom of the slab, reacting with the glassy phase components in the bottom of the slab. This creates recessed textures on the surface of the bottom of the slab, forming micropores. This ensures smooth penetration of the adhesive into the bottom of the slab later, thereby improving the bonding strength between the slab and the substrate. Since the bottom of the slab is mainly composed of mullite phase with a small amount of glassy phase, and some glassy phase is even covered by mullite phase, resulting in an uneven and scattered distribution of the glassy phase, this invention first applies fluoride, followed by acid, to avoid passivation of the reaction surface and incomplete reaction, ensuring the formation of micropores.

[0072] Preferably, fluoride is first added to the bottom of the slab using a roller coating process, followed by acid addition via a spray coating process. During the coating process, tools such as brushes are used for mixing, simultaneously generating hydrofluoric acid and reacting with a small amount of glass phase on the surface. Then, through the pores formed by the surface reaction, it slowly reacts with the internal glass phase. This not only promotes a smoother and more uniform reaction but also effectively avoids the harmful effects of hydrogen fluoride volatilization when directly applying the mixture. This invention creates recessed textures on the surface of the bottom of the slab using the above method, forming micropores, such as... Figure 1 As shown.

[0073] Figure 1This is a scanning electron microscope (SEM) image of the micropores formed after the fluoride aqueous solution and acid solution are mixed and reacted at the bottom of the slab. The morphology of the micropores was observed using a ZEISS SEM at an accelerating voltage (EHT) of 20.00 kV and a working distance (WD) of 9.0 mm. The image shows that the bottom of the slab has certain natural pores with a diameter of approximately 1 μm, but the overall structure is relatively dense, making it difficult for the solution to penetrate the slab and react with the internal substances. After the fluoride solution was roller-coated onto the bottom of the slab, followed by the spraying of the acid solution and subsequent coating, the two solutions were mixed, forming irregular micropores with a diameter of 10-20 μm on the surface of the bottom of the slab. This facilitates the penetration of the adhesive later and improves the bonding strength between the slab and the substrate.

[0074] The elemental composition of the rock slab was analyzed by EDS, and the spectra were processed as follows: potentially ignored peaks: 2.143 and 11.461 keV; processing options: all analyzed elements (normalized), number of repetitions = 5; standard samples were: O SiO2 1-Jun-1999 12:00AM; Mg MgO 1-Jun-1999 12:00AM; Al Al2O3 1-Jun-1999 12:00AM; Si SiO2 1-Jun-1999 12:00AM; K MAD-10Feldspar 1-Jun-1999 12:00AM; CaWollastonite 1-Jun-1999 12:00AM; Zn Zn 1-Jun-1999 12:00AM; Ba BaF2 1-Jun-1999 12:00AM.

[0075] The results are shown in Table 1 below.

[0076] Table 1. Elemental content of rock slabs, EDS analysis results

[0077] element weight percentage / % Atomic percentage / % OK 48.76 67.62 Mg K 2.56 2.34 Al K 6.63 5.45 Si K 21.97 17.36 KK 1.43 0.81 Ca K 5.25 2.91 Zn K 7.63 2.59 Ba L 5.76 0.93 Total 100.00 100.00

[0078] As shown in Table 1, the percentage of O atoms in the rock slab with micropores is higher than the sum of all O atoms in the oxides. This proves that adding fluoride to the bottom of the rock slab first through a roller coating process, followed by adding acid through a spray coating process, and mixing with tools such as brushes during the coating process, can react with the glass phase material in the rock slab, thereby promoting the formation of micropores at the bottom of the rock slab.

[0079] In addition, acidic conditions can promote the corrosion and penetration of fluoride ions on the surface of the rock slab, thereby forming deeper textures.

[0080] Furthermore, the fluoride is added in the form of an aqueous solution, preferably sodium fluoride, ammonium fluoride, and potassium fluoride. The preferred aqueous solution comprises: 50-55 parts sodium fluoride, 20-30 parts ammonium fluoride, 10-15 parts potassium fluoride, and 100 parts purified water. The selected fluorides are salts with very weak corrosiveness, and the initial coating will not severely corrode the rock slab. Sodium fluoride, ammonium fluoride, and potassium fluoride are strong electrolytes, and they can undergo ion exchange reactions. The combined use of multiple fluorides effectively promotes the reaction process with acids, accelerates the formation of hydrofluoric acid, and speeds up subsequent reactions. Moreover, sodium fluoride, ammonium fluoride, and potassium fluoride are readily available and inexpensive, facilitating industrial applications.

[0081] Furthermore, in the early stages, the surface of the rock slab contains relatively little glass phase, so not much hydrofluoric acid is needed. In the later stages, as the pores open, hydrofluoric acid can come into contact with more glass phase, requiring more hydrofluoric acid. Therefore, based on the structure of the crystals on the back of the rock slab, the preferred acids include hydrochloric acid, nitric acid, oxalic acid, and sulfuric acid. More preferably, the acids include: 20-25 parts hydrochloric acid, 30-35 parts nitric acid, 40-45 parts oxalic acid, and 10-15 parts sulfuric acid. The combination of strong and weak acids can control the reaction rate, increasing the reaction duration during the reaction with fluorides and promoting a complete reaction. At the same time, it allows the hydrogen fluoride generated later to continue reacting with the silicon tetrafluoride generated in the reaction, avoiding the release of toxic silicon tetrafluoride gas and reducing physiological harm to operators.

[0082] It should be noted that the hydrochloric acid, nitric acid, and sulfuric acid used in this invention are all concentrated acids of the highest available concentration, specifically 37 wt% concentrated hydrochloric acid, 68 wt% concentrated nitric acid, and 98 wt% concentrated sulfuric acid.

[0083] Furthermore, in this invention, by controlling the ratio of fluoride aqueous solution to acid to preferably be 1:(0.8-1.25), the reaction can be ensured to proceed smoothly. Specifically, the amount of both fluoride aqueous solution and acid is preferably controlled at 8-10 grams per square meter. By controlling the amount, the degree of reaction between fluoride and acid and the slab can be adjusted, thereby increasing the concave texture while ensuring the basic performance of the slab, facilitating the penetration of more adhesive, and thus promoting the bonding strength between the slab and different substrate boards.

[0084] Furthermore, when coating with fluoride aqueous solution and acid, V1 and V2 are controlled to be 4-7 m / min, preferably 5-6 m / min, so that the fluoride and aqueous solution have sufficient time to mix evenly and react fully, thereby forming micropores with a pore size of 10-20 μm, so that the adhesive has enough space to penetrate later without damaging the basic structure of the rock slab.

[0085] This invention, by controlling the amount of fluoride aqueous solution, acid, and the linear speed of the conveyor belt, can promote the reaction between fluoride and aqueous acid, which is conducive to the formation of micropores and increases the bonding strength and drop ball impact strength of the composite rock slab.

[0086] In this invention, in step S2, the heat treatment process can further promote the reaction. The temperature of the rock slab after heat treatment is preferably 40-45°C, which can accelerate the reaction rate of fluoride and acid in aqueous solution, and at the same time enable the generated hydrogen fluoride to fully react with the glass phase components, thereby accelerating the reaction rate. After the reaction is completed, the residual liquid can be rinsed with water.

[0087] In this invention, in step S3, a roller coating process is used to apply the adhesive. Specifically, the adhesive is applied while heating. First, the slab is heated to 50-85°C, preferably 50-70°C. Then, the adhesive is applied to the bottom of the slab, mainly to evaporate water and ensure the bottom of the slab is dry, preventing the generated fluorosilicone from reacting in the aqueous solution and affecting the composite effect. Simultaneously, the temperature of the slab is increased to near the melting temperature of the adhesive, accelerating the subsequent penetration of the adhesive into the micropores. The slab is then heated further until its temperature reaches 70-95°C, preferably 70-75°C. This allows the adhesive to maintain its fluidity, preventing rapid curing and allowing sufficient time for it to flow into the micropores, ensuring the recesses are filled with adhesive, while also extending the processing time.

[0088] In this invention, both the heating process in S2 and the heating state in S3 allow the slab to be placed on a transmission belt and kept moving at a certain linear speed to promote the full progress of each reaction step and accelerate production efficiency. Specifically, V3 is controlled to be <V1 or V2, and V3 > V4. When V1 or V2 > V3 > V4, the fluoride aqueous solution and acid can be quickly and evenly mixed and reacted. Subsequently, the speed is slowed down in S2 to allow the slab to react more fully under heating. Then, the linear speed is reduced again in S3 to allow the adhesive to be evenly coated and sufficient time to form micropores on the bottom surface of the slab after coating.

[0089] Furthermore, controlling V3 to 2.5-5 m / min ensures a complete reaction. If the linear velocity is too high, the reaction will be incomplete, failing to form effective micropores and resulting in greater waste of raw materials. Preferably, V3 is 3-4.5 m / min, and more preferably, V3 is 3-4 m / min.

[0090] Furthermore, controlling the velocity V4 to 0.5-3 m / min ensures sufficient contact between the adhesive and the rock slab, allowing it to penetrate the micropores. Excessive linear velocity leads to uneven adhesive application, thus reducing the bonding performance of the composite rock slab. Preferably, V4 is 1-2.5 m / min; more preferably, V4 is 1-2 m / min.

[0091] Furthermore, after applying the adhesive in S3, keeping the linear speed of the drive belt constant allows the adhesive to penetrate the micropores better in a flowing state, ensuring that the adhesive is present in all micropores. If the linear speed is increased, the amount of adhesive in the micropores will decrease, and the adhesive will become more fluid, resulting in uneven distribution of adhesive on the bottom surface of the slab, reducing the bonding performance of the composite slab, and shortening the operation time.

[0092] In this invention, PUR hot melt adhesive is preferentially selected as the adhesive. PUR hot melt adhesive is easy to apply after melting and can be quickly used to bond the slab layer and the substrate after cooling. It also has good initial tack, instantly bonding the slab and substrate without rebound. Furthermore, the PUR hot melt adhesive layer, after undergoing an oxidation reaction between the composite panels, solidifies again and retains a certain degree of toughness. In addition, the PUR hot melt adhesive in the texture of the slab, after cooling and solidifying with the bottom surface, becomes a unified whole. By reasonably controlling the adhesive thickness to 0.4-0.5mm, the bonding strength is further increased, as is the impact resistance and flexural strength of the composite slab. It will not melt when exposed to high temperatures again, preventing separation between the slab and the substrate and minimizing safety hazards.

[0093] Furthermore, the processing performance is even better if the board is placed on a flat surface and allowed to cool and solidify for 24 hours before processing.

[0094] In summary, the preparation method of the present invention can achieve bonding between sintered stone and various different substrate boards. Moreover, the preparation method is simple, and the resulting composite sintered stone has good bonding performance, high impact resistance, and high flexural strength.

[0095] Accordingly, the present invention also provides an assembled composite rock panel prepared according to the above preparation method.

[0096] Furthermore, the prefabricated composite rock panels prepared by the above-described simple process can be widely used in walls, floors, doors, cabinets, ceilings, dining tables, and other applications.

[0097] For example, sintered stone composite bamboo charcoal board can be used for walls, doors, cabinets, cabinet doors, and countertops; sintered stone composite calcium silicate board can be used for floors; sintered stone composite stainless steel substrate board can be used for dining tables; sintered stone can be combined with different materials to meet the processing needs of different application scenarios.

[0098] The present invention will be further described below with reference to specific embodiments:

[0099] Example 1

[0100] This embodiment provides a prefabricated composite rock panel, the preparation method of which includes:

[0101] S1. Prepare an aqueous solution of fluoride and an acid; wherein, the aqueous solution of fluoride is prepared by dissolving 40 parts of sodium fluoride, 10 parts of ammonium fluoride and 5 parts of potassium fluoride in 100 parts of purified water and stirring evenly; the acid is prepared by mixing 15 parts of hydrochloric acid, 20 parts of nitric acid, 30 parts of oxalic acid and 5 parts of sulfuric acid evenly.

[0102] S2. Use a wire brush to physically clean the bottom of the rock slab to remove aluminum oxide or magnesium oxide;

[0103] S3. Apply the prepared fluoride aqueous solution evenly to the bottom of the rock slab using a roller at a rate of 9 grams per square meter. Then, use a spraying process to apply the prepared acid at a rate of 9 grams per square meter to the bottom of the rock slab that has already been coated with the fluoride aqueous solution. Use a brush to mix the two together evenly.

[0104] S4. Heat the rock slab to 40-45℃ to accelerate the reaction and evaporate the liquid;

[0105] S5. Heat the slab to 50-60℃, apply the PUR hot melt adhesive (melted at 120℃) to the bottom of the slab using a roller, and apply the composite adhesive with a thickness of 0.4-0.5mm. Continue heating to 70-75℃ to keep the adhesive fluid and allow it to flow into the micropores, ensuring that the depressions are covered with adhesive. Then proceed with the board lamination.

[0106] Example 2

[0107] This embodiment provides a prefabricated composite rock panel, the preparation method of which includes:

[0108] S1. Prepare an aqueous solution of fluoride and an acid; wherein, the aqueous solution of fluoride is prepared by dissolving 40 parts of sodium fluoride, 10 parts of ammonium fluoride and 5 parts of potassium fluoride in 100 parts of purified water and stirring evenly; the acid is prepared by mixing 15 parts of hydrochloric acid, 20 parts of nitric acid, 30 parts of oxalic acid and 5 parts of sulfuric acid evenly.

[0109] S2. Use a wire brush to physically clean the bottom of the rock slab to remove aluminum oxide or magnesium oxide;

[0110] S3. The prepared fluoride aqueous solution is evenly roller-coated onto the bottom of the rock slab at a dosage of 9 grams per square meter. The linear speed of the drive belt used to transport the rock slab is 5 meters per minute. Then, the prepared acid is evenly sprayed onto the bottom of the rock slab that has been roller-coated with the fluoride aqueous solution at a dosage of 9 grams per square meter. The linear speed of the drive belt used to transport the rock slab is 5 meters per minute. During the spraying process, the two liquids are continuously mixed evenly with a brush to allow them to react with the glass phase components.

[0111] S4. First heat the rock slab to 40-45℃, and the linear speed of the drive belt used to transport the rock slab is 3.5 m / min, and then rinse it with running water;

[0112] S5. Heat the slab to 60-65℃. The linear speed of the drive belt used to transport the slab is 1.5 m / min. Apply PUR hot melt adhesive, which has been melted at 120℃, to the bottom of the slab. The thickness of the adhesive layer is 0.4 mm. Continue heating to 70-75℃ while keeping the linear speed constant to keep the PUR hot melt adhesive fluid and allow it to flow into the micropores. Then, use laser positioning and mechanical clamping to composite the bottom of the slab with the substrate board. The deviation between the slab and the substrate board in the longitudinal and / or transverse directions is < ±0.5 mm. Finally, press the slab and the substrate board together using a roll pressing process. The distance between the upper and lower rollers of the roll pressing process is 3 mm smaller than that of the composite board.

[0113] S6. Place the obtained composite rock slab on a flat ground and allow it to cool and solidify for 24 hours. Then, further process it to obtain the assembled composite rock slab.

[0114] Example 3

[0115] This embodiment provides a prefabricated composite rock panel, which differs from Embodiment 2 in that:

[0116] In S1, the fluoride aqueous solution, by weight, is made by dissolving 60 parts of sodium fluoride, 35 parts of ammonium fluoride and 20 parts of potassium fluoride in 100 parts of purified water and stirring until homogeneous; the acid, by weight, is made by mixing 35 parts of hydrochloric acid, 45 parts of nitric acid, 55 parts of oxalic acid and 25 parts of sulfuric acid until homogeneous.

[0117] Example 4

[0118] This embodiment provides a prefabricated composite rock panel, which differs from Embodiment 2 in that:

[0119] In S1, the aqueous solution of fluoride is prepared by dissolving 55 parts of sodium fluoride, 30 parts of ammonium fluoride, and 15 parts of potassium fluoride in 100 parts of purified water and stirring until homogeneous. The acid is prepared by mixing 25 parts of hydrochloric acid, 35 parts of nitric acid, 45 parts of oxalic acid, and 15 parts of sulfuric acid until homogeneous.

[0120] Example 5

[0121] This embodiment provides a prefabricated composite rock panel, which differs from Embodiment 2 in that:

[0122] In S1, the fluoride aqueous solution is prepared by dissolving 50 parts of sodium fluoride, 20 parts of ammonium fluoride, and 10 parts of potassium fluoride in 100 parts of purified water and stirring until homogeneous. The acid is prepared by mixing 20 parts of hydrochloric acid, 30 parts of nitric acid, 40 parts of oxalic acid, and 10 parts of sulfuric acid until homogeneous.

[0123] Example 6

[0124] This comparative example provides a prefabricated composite rock panel, which differs from Example 3 in that:

[0125] In S1, the acid is composed of 35 parts hydrochloric acid, 45 parts nitric acid, 55 parts citric acid, and 25 parts sulfuric acid, mixed evenly by weight.

[0126] Example 7

[0127] This comparative example provides a prefabricated composite rock panel, which differs from Example 1 in that:

[0128] In S5, the temperature of the slab is 40-45℃, and the PUR hot melt adhesive, which has been melted at 120℃, is applied to the bottom of the slab by roller.

[0129] Comparative Example 1

[0130] This comparative example provides a prefabricated composite rock panel, the preparation method of which includes:

[0131] S1. The back of the rock slab is subjected to a first sandblasting treatment using sand with a first particle size of 0.1-0.2 mm, with the angle between the sand nozzle and the back of the rock slab being 85°. Then, the back of the rock slab after the first sandblasting treatment is subjected to a second sandblasting treatment using sand with a second particle size of 0.6-0.7 mm, with the angle between the sand nozzle and the back of the rock slab being 40°. Finally, the back of the rock slab after the second sandblasting treatment is subjected to a third sandblasting treatment using sand with a third particle size of 0.3-0.4 mm, with the angle between the sand nozzle and the back of the rock slab being 75°.

[0132] S2. Heat the rock slab to 40-45℃ to accelerate the reaction and evaporate the liquid;

[0133] S3. Heat the slab to 50-60℃, apply the PUR hot melt adhesive (melted at 120℃) to the bottom of the slab using a roller, and apply the composite adhesive with a thickness of 0.4-0.5mm. Continue heating to 70-75℃ to keep the adhesive fluid and allow it to flow into the micropores, ensuring that the depressions are covered with adhesive. Then proceed with the slab lamination.

[0134] Performance Testing: According to the preparation methods in Examples 1-5 and Comparative Examples 1-5, composite slabs were obtained by combining the slabs with calcium silicate boards and bamboo charcoal boards, respectively. The bonding strength of the obtained composite slabs was tested. The testing criteria and indicators for flexural strength and bonding strength were based on GB / T 29059-2012 Ultra-thin Stone Composite Boards. The test method for resistance to falling ball impact was conducted according to standard JG / T 463-2014 Artificial Quartz Stone Boards for Building Decoration.

[0135] The results are shown in Tables 2 and 3 below:

[0136] Table 2 Bond strength of composite rock slab and calcium silicate board

[0137] Flexural strength / MPa Bond strength / MPa Impact resistance of falling balls / J Example 1 49.7 1.6 5.1 Example 2 50.1 1.8 6.2 Example 3 48.5 1.8 5.5 Example 4 47.0 1.4 6.0 Example 5 50.2 1.6 5.8 Example 6 47 1.5 5.0 Example 7 48 1.3 4.8 Comparative Example 1 45 1.2 4.5

[0138] Table 3 Bond strength of composite rock slab and bamboo charcoal board

[0139] Flexural strength / MPa Bond strength / MPa Impact resistance of falling balls / J Example 1 55 1.5 4.0 Example 2 55.6 1.7 4.1 Example 3 52 1.8 4.5 Example 4 51 1.6 4.0 Example 5 55 1.5 4.3 Example 6 50 1.3 4.5 Example 7 54 1.3 4.2 Comparative Example 1 50 1.3 4.0

[0140] As can be seen from the above data, by using the preparation method of the present invention, selecting a specific fluoride aqueous solution and acid to treat the bottom of the rock slab in a stepwise mixture, the composite board is more firmly bonded, and the flexural strength, bonding strength and drop ball impact value are all ideal, and the safety is further improved.

[0141] The above description is merely a preferred embodiment of the present invention and should not be construed as limiting the scope of the invention. Therefore, any equivalent variations made in accordance with the claims of the present invention are still within the scope of the present invention.

Claims

1. A method for preparing a fabricated composite rock panel, characterized by, The method comprises the following steps: S1. Coating fluoride and acid on the bottom of the rock plate to form micro-channels; S2. Heating the rock plate obtained in S1; S3. Coating adhesive on the bottom of the rock plate obtained in S2 under heating conditions so that the adhesive penetrates into the micro-channels; S4. Bonding the rock plate obtained in S3 with a base plate to obtain a composite rock plate; In S1, the fluoride is first coated on the bottom of the rock plate, and then the acid is continuously coated, and the two are uniformly mixed during the coating process, wherein the fluoride is added in the form of a fluoride aqueous solution; The fluoride aqueous solution comprises, by weight fraction, 40-65 parts of sodium fluoride, 10-40 parts of ammonium fluoride, 5-25 parts of potassium fluoride, and 100 parts of pure water; The acid comprises, by weight fraction, 15-35 parts of hydrochloric acid, 20-45 parts of nitric acid, 30-55 parts of oxalic acid, and 5-25 parts of sulfuric acid; The use amount ratio of the fluoride aqueous solution to the acid is 1:(0.6-1.6); In S1, the linear speed of the transmission belt for conveying the rock plate when coating the fluoride aqueous solution is V1, the linear speed of the transmission belt for conveying the rock plate when coating the acid is V2, and the linear speed of the transmission belt for conveying the rock plate when heating in S2 is V3; in S3, the linear speed of the transmission belt for conveying the rock plate when coating the adhesive is V4; wherein V3V3>V4.

2. The method of claim 1, wherein the method further comprises: In S2, the temperature of the rock plate after heating treatment is controlled to be 35-48℃; In S3, the heating conditions comprise: first heating the rock plate to 50-85℃, and then coating adhesive on the bottom of the rock plate; continuing to heat the rock plate until its temperature is 70-95℃.

3. The method of claim 1, wherein the method further comprises: In S1, the coating method of the fluoride aqueous solution is roller coating, and the use amount of the fluoride aqueous solution is 7-11 g / m2; The coating method of the acid is spraying, and the use amount of the acid is 7-11 g / m2.

4. The method of claim 1 or 3, wherein the method further comprises: V1=4-7 m / min; V2=4-7 m / min.

5. The method of claim 1, wherein the fabricated composite rock panel is prepared by the steps of: V3=2.5-5 m / min, and V4=0.5-3 m / min.

6. The method of claim 1, wherein the fabricated composite rock panel is prepared by the steps of: In S3, the adhesive is PUR hot melt adhesive, and the coating thickness of the adhesive is 0.3-0.7 mm; and / or, the adhesive is subjected to high-temperature hot melting treatment at 110-130℃ before coating.

7. The method of claim 1, wherein the fabricated composite rock panel is prepared by the steps of: In S4, bonding the rock plate obtained in S3 with the base plate further comprises laser positioning, mechanical clamping, and roller pressing process.

8. The method of claim 7, wherein the method further comprises: In S4, the distance between the upper and lower rollers for roller pressing process is controlled to be 2.5-5 mm different from the thickness of the composite rock plate.

9. The method of claim 1, wherein the fabricated composite rock panel is prepared by the steps of: In S4, the base plate is one or a combination of a calcium silicate plate, a bamboo charcoal plate, and stainless steel.

10. A fabricated composite rock plate prepared by the method according to any one of claims 1-9.

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