Processing method for improving the flame retardancy of artificial quartz stone

Abstract

The application provides a processing method for improving the flame retardance of artificial quartz stone, and relates to the technical field of artificial quartz stone.The surface of artificial quartz stone plate is polished and cleaned, and then dried; the pretreated artificial quartz stone plate is placed in a coating liquid, soaked for 10-20 hours at a temperature of 30-50 DEG C, taken out after the soaking, and then drained for standby; the coating liquid comprises epoxy resin, zinc stearate, sodium dodecylbenzenesulfonate, nano silicon dioxide, nano zinc oxide, aluminum hypophosphite, a dispersing agent, a curing agent and pigments; finally, the surface-coated artificial quartz stone plate is cured for 1-3 hours at a temperature of 120-150 DEG C.The application coats a flame-retardant layer on the surface of the conventional artificial quartz stone plate, thereby significantly improving the flame-retardant property of the artificial quartz stone, and the flame-retardant layer constructed by the application has strong bonding force with the base layer of the artificial quartz stone and is not easy to fall off.The flame-retardant layer formed by the application also has high hardness and wear resistance.

Description

Technical Field

[0001] This invention relates to the field of artificial quartz stone technology, and in particular to a processing method for improving the flame retardancy of artificial quartz stone. Background Technology

[0002] Artificial quartz stone is composed of over 90% natural quartz and approximately 10% colorants, resins, and other additives for adjusting adhesion and curing. It is made into slabs through negative pressure vacuum molding, high-frequency vibration, and heat curing.

[0003] Artificial quartz stone possesses high surface hardness (Mohs hardness 6-7), scratch resistance, wear resistance, impact resistance, bending resistance, compression resistance, high temperature resistance, corrosion resistance, and impermeability. In certain specialized fields, there are specific regulations regarding the flame retardancy of artificial quartz stone. Therefore, artificial quartz stone manufacturers need to process their existing products to ensure that their flame retardancy meets relevant regulations. Summary of the Invention

[0004] In view of this, the present invention provides a processing method for improving the flame retardancy of artificial quartz stone. The present invention involves forming a flame-retardant layer on the surface of the artificial quartz stone. This flame-retardant layer not only possesses high flame-retardant properties but also high hardness and wear resistance.

[0005] This invention is achieved using the following technical solution:

[0006] A processing method for improving the flame retardancy of artificial quartz stone includes the following steps:

[0007] S1. Preprocessing:

[0008] After polishing and cleaning the surface of the artificial quartz stone slab, let it air dry.

[0009] S2, Surface coating:

[0010] The pretreated artificial quartz stone slabs are placed in a coating solution and soaked at a temperature of 30℃~50℃ for 10h~20h. After soaking, they are taken out, drained and set aside for later use. The coating solution includes epoxy resin, zinc stearate, sodium dodecanephenyl sulfonate, nano silica, nano zinc oxide, aluminum hypophosphite, dispersant, curing agent and pigment.

[0011] S3. Cure the coated artificial quartz stone slabs at a temperature of 120-150℃ for 1-3 hours.

[0012] Preferably, the pretreatment in step S1 involves polishing the surface of the artificial quartz stone with a polishing machine until smooth, and then cleaning it multiple times with water and ethanol in sequence.

[0013] Preferably, the weight parts of each raw material in the coating liquid are as follows:

[0014] 10-20 parts epoxy resin, 5-10 parts zinc stearate, 3-5 parts sodium dodecylbenzene sulfonate, 2-5 parts nano silica, 2-5 parts nano zinc oxide, 1-3 parts aluminum hypophosphite, 10-15 parts dispersant, 1-2 parts curing agent, and 0-0.5 parts pigment.

[0015] More preferably, the dispersant is a mixture of polystyrene and sodium dodecyl sulfonate.

[0016] More preferably, the mass ratio of polystyrene to sodium dodecyl sulfonate in the dispersant is 1-3:8-10.

[0017] Preferably, the curing agent is an acid anhydride-based curing agent.

[0018] More preferably, the anhydride curing agent is phthalic anhydride.

[0019] Compared with the prior art, the present invention has the following beneficial effects:

[0020] This invention involves coating a flame-retardant layer onto the surface of traditional artificial quartz stone slabs, thereby significantly improving the flame-retardant properties of the artificial quartz stone. Furthermore, the flame-retardant layer constructed by this invention exhibits strong adhesion to the artificial quartz stone base layer, making it less prone to detachment. The flame-retardant layer formed by this invention also possesses high hardness and wear resistance. Detailed Implementation

[0021] The present invention will be further described below with reference to the embodiments.

[0022] The artificial quartz stone slabs used in the following embodiments of the present invention are prepared by the method of Embodiment 1 of patent CN102627429A. The specific preparation steps are as follows:

[0023] A raw material for artificial quartz stone slabs is composed of solid materials and additives. The solid materials, by weight percentage, consist of: 58% quartz sand with a particle size of 4-140 mesh, 32% quartz powder with a particle size of 325-1250 mesh, and 10% unsaturated polyester resin. The additives are a curing agent and a coupling agent. The curing agent is 2.0% by weight of tert-butyl peroxide-2-ethylhexanoate equal to the weight of the unsaturated polyester resin. The coupling agent is a commercially available organosilane coupling agent with trade name KH580, and its weight is 1.5% by weight of the unsaturated polyester resin. The viscosity of the unsaturated polyester resin is 1.0 MPa·S. The unsaturated polyester resin contains 65% styrene by weight and 35% unsaturated polyester by weight.

[0024] The method for preparing artificial quartz stone slabs using the above-mentioned raw materials includes the following steps in sequence:

[0025] 1) Weigh out the quartz sand, quartz powder, unsaturated polyester resin, curing agent, and coupling agent according to the above component design requirements, and stir and mix them evenly;

[0026] 2) Select a template of a certain size and spread the mixed material evenly on the template;

[0027] 3) The template is fed into the vacuum vibration forming press and vibrated to form the shape. The vacuum degree in the vacuum vibration forming press is controlled at -0.08MPa, the working frequency of the vacuum vibration forming press is controlled at 50Hz, the static pressure on the press head of the vacuum vibration forming press is controlled at 30kg, and the pressing time is controlled at 5min.

[0028] 4) The molded board is sent into a microwave curing oven for heating and curing. The microwave emission frequency of the microwave curing oven is controlled at 2450MHz, the temperature inside the microwave curing oven is controlled at 80℃, and the heating is carried out for 40 minutes to completely cure the board.

[0029] 5) After the cured slabs are removed from the oven, they are demolded, stacked, and cooled to cure at room temperature for 2 days to obtain artificial quartz stone slabs.

[0030] Example 1

[0031] A processing method for improving the flame retardancy of artificial quartz stone, comprising the following steps:

[0032] S1. Preprocessing:

[0033] Using artificial quartz stone slabs as a base, the surface is polished smooth with a grinding machine, and then cleaned repeatedly with water and ethanol, and then dried for later use.

[0034] S2, Surface coating:

[0035] The pretreated artificial quartz stone slabs were placed in a coating solution and soaked at 45°C for 15 hours. After soaking, they were removed, drained, and set aside for later use. The coating solution was composed of the following raw materials in parts by weight:

[0036] The mixture comprises 15 parts epoxy resin, 8 parts zinc stearate, 4 parts sodium dodecylbenzene sulfonate, 3 parts nano silica, 2 parts nano zinc oxide, 2 parts aluminum hypophosphite, 10 parts dispersant, and 1 part curing agent (phthalic anhydride); wherein the mass ratio of polystyrene to sodium dodecylbenzene sulfonate in the dispersant is 1:8.

[0037] S3. Cure the coated artificial quartz stone slab at 120℃ for 2 hours.

[0038] Example 2

[0039] A processing method for improving the flame retardancy of artificial quartz stone, comprising the following steps:

[0040] S1. Preprocessing:

[0041] Using artificial quartz stone slabs as a base, the surface is polished smooth with a grinding machine, and then cleaned repeatedly with water and ethanol, and then dried for later use.

[0042] S2, Surface coating:

[0043] The pretreated artificial quartz stone slabs were placed in a coating solution and soaked at 45°C for 15 hours. After soaking, they were removed, drained, and set aside for later use. The coating solution was composed of the following raw materials in parts by weight:

[0044] The composition includes 10 parts epoxy resin, 5 parts zinc stearate, 3 parts sodium dodecylbenzene sulfonate, 2 parts nano silica, 2 parts nano zinc oxide, 1 part aluminum hypophosphite, 10 parts dispersant, 1 part curing agent (phthalic anhydride), and 0.1 parts pigment; the mass ratio of polystyrene to sodium dodecylbenzene sulfonate in the dispersant is 2:9.

[0045] S3. Cure the coated artificial quartz stone slab at 120℃ for 2 hours.

[0046] Example 3

[0047] A processing method for improving the flame retardancy of artificial quartz stone, comprising the following steps:

[0048] S1. Preprocessing:

[0049] Using artificial quartz stone slabs as a base, the surface is polished smooth with a grinding machine, and then cleaned repeatedly with water and ethanol, and then dried for later use.

[0050] S2, Surface coating:

[0051] The pretreated artificial quartz stone slabs were placed in a coating solution and soaked at 45°C for 15 hours. After soaking, they were removed, drained, and set aside for later use. The coating solution was composed of the following raw materials in parts by weight:

[0052] The composition includes 20 parts epoxy resin, 10 parts zinc stearate, 3 parts sodium dodecylbenzene sulfonate, 2 parts nano silica, 5 parts nano zinc oxide, 3 parts aluminum hypophosphite, 10 parts dispersant, 2 parts curing agent (phthalic anhydride), and 0.5 parts pigment; the mass ratio of polystyrene to sodium dodecylbenzene sulfonate in the dispersant is 3:8.

[0053] S3. Cure the coated artificial quartz stone slab at 120℃ for 2 hours.

[0054] Example 4

[0055] A processing method for improving the flame retardancy of artificial quartz stone, comprising the following steps:

[0056] S1. Preprocessing:

[0057] Using artificial quartz stone slabs as a base, the surface is polished smooth with a grinding machine, and then cleaned repeatedly with water and ethanol, and then dried for later use.

[0058] S2, Surface coating:

[0059] The pretreated artificial quartz stone slabs are placed in a coating solution and soaked at 50°C for 10 hours. After soaking, they are removed, drained, and set aside for later use. The coating solution is a mixture of the following raw materials in parts by weight:

[0060] The mixture comprises 18 parts epoxy resin, 7 parts zinc stearate, 5 parts sodium dodecylbenzene sulfonate, 5 parts nano silica, 5 parts nano zinc oxide, 1 part aluminum hypophosphite, 15 parts dispersant, and 1 part curing agent (phthalic anhydride); wherein the mass ratio of polystyrene to sodium dodecylbenzene sulfonate in the dispersant is 3:10.

[0061] S3. Cure the coated artificial quartz stone slab at 150℃ for 1 hour.

[0062] Example 5

[0063] A processing method for improving the flame retardancy of artificial quartz stone, comprising the following steps:

[0064] S1. Preprocessing:

[0065] Using artificial quartz stone slabs as a base, the surface is polished smooth with a grinding machine, and then cleaned repeatedly with water and ethanol, and then dried for later use.

[0066] S2, Surface coating:

[0067] The pretreated artificial quartz stone slabs are placed in a coating solution and soaked at 30°C for 20 hours. After soaking, they are removed, drained, and set aside for later use. The coating solution is a mixture of the following raw materials in parts by weight:

[0068] The composition includes 12 parts epoxy resin, 6 parts zinc stearate, 3 parts sodium dodecylbenzene sulfonate, 3 parts nano silica, 3 parts nano zinc oxide, 3 parts aluminum hypophosphite, 15 parts dispersant, 1 part curing agent (phthalic anhydride), and 0.2 parts pigment; the mass ratio of polystyrene to sodium dodecylbenzene sulfonate in the dispersant is 1:10.

[0069] S3. Cure the coated artificial quartz stone slab at 150℃ for 2 hours.

[0070] The oxygen index of Examples 1-5 and untreated artificial quartz stone slabs (blank examples) was tested according to the method of JC / T 908-2013, and the results are as follows:

[0071]

[0072]

[0073] Meanwhile, testing revealed that the hardness and wear resistance of the artificial quartz stone slabs treated in Examples 1-5 of this invention were not significantly different from those of the blank example.

[0074] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A processing method for improving the flame retardancy of artificial quartz stone, characterized in that, Includes the following steps: S1. Preprocessing: The artificial quartz stone slabs are polished smooth using a grinding machine, and then cleaned multiple times with water and ethanol in sequence. S2, Surface coating: The pretreated artificial quartz stone slabs are placed in a coating solution and soaked at a temperature of 30℃~50℃ for 10 h~20 h. After soaking, they are removed, drained, and set aside for later use. The coating solution includes epoxy resin, zinc stearate, sodium dodecyl phenyl sulfonate, nano silica, nano zinc oxide, aluminum hypophosphite, dispersant, curing agent, and pigment. The dispersant is a mixture of polystyrene and sodium dodecyl sulfonate, wherein the mass ratio of polystyrene to sodium dodecyl sulfonate is 1~3:8~10. S3. Curing the coated artificial quartz stone slab at a temperature of 120~150℃ for 1-3 hours; The weight proportions of each raw material in the coating liquid are as follows: 10-20 parts epoxy resin, 5-10 parts zinc stearate, 3-5 parts sodium dodecylbenzene sulfonate, 2-5 parts nano silica, 2-5 parts nano zinc oxide, 1-3 parts aluminum hypophosphite, 10-15 parts dispersant, 1-2 parts curing agent, and 0-0.5 parts pigment.

2. The processing method for improving the flame retardancy of artificial quartz stone according to claim 1, characterized in that, The curing agent is an acid anhydride-based curing agent.

3. The processing method for improving the flame retardancy of artificial quartz stone according to claim 2, characterized in that, The anhydride curing agent is phthalic anhydride.

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