Manufacturing process of table top with high abrasion resistance

Abstract

The invention relates to the technical field of table top manufacturing, and discloses a high-abrasion-resistance table top manufacturing process which comprises the steps of material preparation, material processing, coating treatment and assembly ending, in the material preparation stage, field investigation needs to be conducted on a construction site firstly, the size of the needed table top is measured, and the needed table top is manufactured; according to the manufacturing process of the table top with the high abrasion resistance, quartz stone is adopted as a base material, and the epoxy primer, the epoxy abrasion-resistant paint and the fluorine-containing polymer protective agent are sequentially sprayed on the surface of the quartz stone, so that a multi-layer abrasion-resistant protective system is formed. The quartz stone has higher hardness, the primer can enhance the adhesive force between the coating and the surface of the quartz stone, the wear-resistant paint further provides a hard wear-resistant layer, and the fluorine-containing polymer protective agent forms a protective film on the surface, so that various friction and scratches in daily use are effectively resisted, the possibility of generating scratches is remarkably reduced, and the service life of the coating is prolonged. And the service life of the table board is greatly prolonged.

Description

Technical Field

[0001] The invention relates to the technical field of countertop manufacturing, in particular to a process for manufacturing a countertop with high wear resistance. Background Art

[0002] In modern homes and commercial places, countertops, as components with high frequency of use, face many challenges. With the improvement of people's quality of life and the diversified needs of various commercial activities, the performance requirements for countertops are becoming increasingly stringent. Traditional countertop materials are prone to scratches due to daily friction and scraping during long-term use, which not only affects the appearance, but also may reduce the service life of the countertop. For example, wooden countertops are easily deformed by moisture and have poor wear resistance. Although ordinary stone countertops are relatively strong, it is difficult to maintain an intact surface for a long time when dealing with frequent cutting, collisions and friction. At the same time, some countertops perform poorly in terms of anti-fouling performance. Stains can easily penetrate into the interior of the countertop, making it difficult to clean, which brings great inconvenience to users. In addition, in different usage scenarios, the countertop needs to have the ability to flexibly connect with a variety of bases or surrounding facilities to meet diverse installation needs, and the adaptability of traditional countertops in this regard is often limited. For this reason, we propose a countertop manufacturing process with high wear resistance. Summary of the invention

[0003] The purpose of the present invention is to provide a process for manufacturing a table top with high wear resistance to solve the problems raised in the above background technology.

[0004] To achieve the above object, the present invention provides the following technical solutions: a process for manufacturing a countertop with high wear resistance, the process for manufacturing a countertop with high wear resistance comprising: material preparation, material processing, coating treatment and assembly finishing; In the material preparation stage, it is necessary to first conduct an on-site survey of the construction site, measure the required countertop dimensions, and prepare quartz stone, glue, hardware accessories, cleaning agents, primers, wear-resistant paints, stone protective agents, adhesive materials, and sandpaper; In the material processing stage, use a cutting machine to split the quartz stone until it is cut to the required size to obtain a preliminary countertop. Use a grinder to grind the cut quartz stone to remove scratches and stains on the surface of the quartz stone material and enhance the adhesion of the coating. Use detergent and water to clean the polished quartz stone to ensure that the surface is clean. After cleaning, wait for the quartz stone countertop to dry completely. Use steel to weld the bottom plate frame and reserve through grooves. Open holes at the bottom of the quartz stone countertop and install the steel at the bottom of the quartz stone countertop with bolts. Through the reserved through grooves at the bottom of the steel, it can be connected to bases of different specifications. When connecting, you only need to connect the steel to the base with bolts to achieve the diversity of countertop use. In the coating treatment stage, use a spray gun to spray the primer, wear-resistant paint and stone protective agent. After spraying, place the quartz countertop in a ventilated place to fully dry, which can effectively improve the wear resistance of the quartz countertop, significantly reduce the possibility of scratches, and have good stain resistance; In the final stage of assembly, use adhesive material to stick to the edge of the quartz countertop with glue and use a rubber roller to compact it. Then install the whole on the preset base. Align the preset base with the through groove on the steel frame at the bottom of the countertop and install it with bolts. This can effectively improve the strength of the edges and corners of the quartz countertop surface and further improve the wear resistance of the countertop.

[0005] Preferably, the quartz countertop is ventilated for 24-48 hours during the coating treatment stage, which can effectively ensure the adhesion of the primer, wear-resistant paint and stone protective agent.

[0006] Preferably, the cutting and polishing of quartz stone in the material processing stage must ensure accuracy. When polishing, first use 80-100 mesh coarse sandpaper for polishing to remove cutting marks and large flaws on the surface, and then use 200 mesh, 400 mesh, 800 mesh, and 1200 mesh sandpaper for fine polishing in sequence to make the countertop surface very smooth, reduce surface roughness, and thus reduce the chance of scratches.

[0007] Preferably, in the material processing stage, connecting the steel material with the quartz countertop includes the following specific steps: First, determine the installation position of the anchor bolts on the bottom of the quartz countertop and the steel frame, and mark them. This step needs to ensure that the position is accurate so that the steel frame can fit tightly with the quartz countertop. Use an electric drill to drill holes at the marked locations according to the specifications of the anchor bolts; Use a hair dryer to clean the dust and debris in the borehole, put the chemical agent into the bottom of the borehole, and use a tool to slowly rotate the screw into the borehole so that the chemical agent is evenly distributed between the screw and the borehole wall; Align the mounting holes of the steel frame with the inserted screws, then use nuts and washers to fix the steel frame to the bottom of the quartz countertop, and tighten the nuts to effectively ensure the fastening between the steel frame and the quartz countertop.

[0008] Preferably, the anchor bolt adopts M10 chemical anchor bolt, and the drilling depth needs to be maintained at 110-130 mm.

[0009] Preferably, the primer is epoxy primer, the wear-resistant paint is epoxy wear-resistant paint, and the stone protective agent is fluoropolymer protective agent, which can form a hard protective film on the countertop, effectively resist scratches, and significantly reduce the possibility of scratches.

[0010] Preferably, the coating treatment stage of spraying primer, wear-resistant paint and stone protective agent includes the following specific steps: Use an HVLP spray gun, set the air pressure at 2-3 bar, and use a nozzle size of 1.3-1.5 mm. Pour the epoxy primer into the container of the spray gun, start the spray gun, and spray at a height of 30-50 cm from the countertop. Start from one end of the countertop and move the spray gun at a uniform speed so that the paint mist falls evenly on the countertop. After the primer is sprayed, clean the spray gun, pour in epoxy wear-resistant paint, and repeat the above steps to spray; After the wear-resistant paint is sprayed, clean the spray gun, set the air pressure at 1.5-2bar, pour in the fluoropolymer protective agent, and when spraying, the spray gun needs to be 40-60cm away from the table. The fluoropolymer protective agent mainly forms a protective film on the surface of the quartz stone, so pay more attention to uniformity when spraying to avoid local inadequate protection.

[0011] Preferably, when spraying the primer in the coating treatment stage, each spraying should overlap appropriately to ensure complete coverage. During the spraying process, the spray gun should be kept vertical to the table to avoid uneven thickness.

[0012] Preferably, the adhesive material is glass fiber reinforced plastic, and the high fiber content and tightly woven structure can increase the strength and scratch resistance of the material.

[0013] Compared with the prior art, the present invention provides a countertop manufacturing process with high wear resistance, which has the following beneficial effects:

[0014] 1. The manufacturing process of this highly wear-resistant countertop uses quartz as the base material and sprays epoxy primer, epoxy wear-resistant paint and fluoropolymer protective agent on its surface in sequence to form a multi-layer wear-resistant protection system. Quartz itself has a high hardness, and the primer can enhance the adhesion between the coating and the quartz surface. The wear-resistant paint further provides a hard wear-resistant layer, and the fluoropolymer protective agent forms a protective film on the surface, which effectively resists various frictions and scratches in daily use, significantly reduces the possibility of scratches, and greatly extends the service life of the countertop.

[0015] 2. The manufacturing process of this highly wear-resistant countertop uses steel to weld the bottom plate frame during the material processing stage, and opens holes at the bottom of the quartz countertop, uses chemical anchor bolts to connect the steel and quartz, and reserves a through groove at the bottom of the steel. This design allows the countertop to be conveniently connected to bases of different specifications through bolts, realizing the diversity of countertop use, meeting various scenarios and installation requirements, and improving the versatility and adaptability of the countertop.

[0016] 3. In the production process of this highly wear-resistant countertop, glass fiber reinforced plastic is used as the adhesive material during the final assembly stage, and is glued to the edge of the quartz countertop with glue, and then compacted with a rubber roller. The high fiber content and tightly woven structure of glass fiber reinforced plastic effectively increase the strength of the corners of the countertop surface, further improving the wear resistance of the entire countertop and avoiding damage to the corners due to collision or friction during use. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic diagram of the process of the present invention; Figure 2 It is a schematic diagram of the specific steps of the present invention. DETAILED DESCRIPTION

[0018] like Figure 1-Figure 2 As shown, the present invention provides a technical solution: a process for manufacturing a countertop with high wear resistance, the process for manufacturing a countertop with high wear resistance comprising: material preparation, material processing, coating treatment and assembly finishing; During the material preparation stage, high-quality quartz slabs with uniform texture, tight crystal structure, and no obvious flaws and cracks should be selected. These characteristics will directly affect the overall strength and aesthetics of the countertop. Glue should be a high-strength, weather-resistant product specially suitable for bonding quartz with steel and adhesive materials. Its bonding strength has been strictly tested and can withstand large shear and tension forces to ensure that the connection between the components is firm. Hardware accessories are also carefully selected. For example, bolts and nuts are made of stainless steel with excellent anti-corrosion performance, and washers have good elasticity and wear resistance to ensure that they will not loosen or be damaged during long-term use. Cleaners should be mild and efficient neutral detergents, which can effectively remove impurities such as oil, dust, etc. on the surface of quartz without causing any erosion or damage to the material of quartz. Primer should be epoxy primer, which has excellent adhesion and sealing properties and can provide a solid foundation for subsequent coatings. Wear-resistant paint is determined to be epoxy wear-resistant paint because it has excellent performance in wear resistance and can form a hard wear-resistant layer. The stone protective agent uses a fluorinated polymer protective agent. With its unique chemical structure and properties, this protective agent can form a tight and stable hard protective film on the countertop, effectively resisting various scratches and significantly reducing the possibility of scratches. The adhesive material is selected as glass fiber reinforced plastic. Its high fiber content and tightly woven structure determine that it can greatly increase the strength and scratch resistance of the material, making it an ideal choice for improving the strength of the countertop corners. Sandpapers are prepared from 80-100 mesh coarse sandpaper for preliminary grinding, and 200 mesh, 400 mesh, 800 mesh, and 1200 mesh fine sandpaper for fine grinding. Sandpapers of different meshes cooperate with each other to achieve the ideal smoothness of the quartz countertop.

[0019] In the material processing stage, the quartz stone is first divided using an advanced CNC cutting machine. This cutting machine can cut quartz stone with extremely high precision according to the pre-set precise size data. The water cooling technology is used during the cutting process to effectively avoid the thermal damage to the quartz stone material caused by the high temperature generated by the cutting, thereby ensuring that the edges of the cut quartz stone are neat and smooth, and minimizing the workload of subsequent grinding. The initial quartz stone countertop after cutting needs to be polished. The grinding machine uses professional stone grinding equipment, and its speed and grinding force can be precisely adjusted. First use 80-100 mesh coarse sandpaper for grinding. During the grinding process, the operator will reciprocate on the surface of the quartz stone with uniform force and speed, focusing on removing the obvious cutting marks and larger defects on the surface caused by cutting, such as tiny cracks, potholes, etc. As the grinding progresses, the surface of the quartz stone gradually becomes flat, and then 200 mesh, 400 mesh, 800 mesh, and 1200 mesh sandpaper are replaced in turn for fine grinding. When using 200-grit sandpaper, the grinding direction will be at a certain angle to the grinding direction of the coarse sandpaper, which can further refine the texture of the quartz surface and make the surface smoother and more delicate. When changing to 400-grit sandpaper, the grinding intensity will be appropriately reduced to avoid causing new scratches on the surface that has been polished flat, mainly to further eliminate the subtle marks left in the previous stage. The grinding of 800-grit sandpaper pays more attention to improving the smoothness of the surface, so that the surface of the quartz begins to show a certain luster. Finally, use 1200-grit sandpaper for polishing and grinding. At this time, the surface of the quartz reaches a very smooth state, its surface roughness is greatly reduced, and the feel is delicate, which greatly reduces the chance of scratches, and also provides a good adhesion basis for subsequent coating treatment.

[0020] After polishing, use detergent and water to clean the polished quartz stone. The operator will use a soft cleaning cloth to dip in an appropriate amount of detergent and carefully wipe every corner of the quartz stone surface to ensure that all impurities such as sandpaper debris, dust, and quartz stone powder left during the polishing process are completely removed. After cleaning, place the quartz stone countertop in a well-ventilated and dry environment and wait for it to dry completely. During the drying process, a hygrometer and thermometer will be used to monitor the ambient humidity and temperature in real time to ensure that the drying environment is stable and suitable. Generally, the ambient humidity is required to be less than 60% and the temperature is between 20-25°C. This can ensure that the moisture inside the quartz stone is fully evaporated to avoid residual moisture affecting the adhesion and quality of subsequent coatings.

[0021] While the quartz stone is drying, high-quality steel is used for welding the bottom plate frame. Welders will strictly follow the design drawings and process requirements and use professional welding equipment, such as argon arc welding machines, to ensure that the welds are uniform, firm, and free of defects such as pores and cracks. After welding, the steel frame will undergo strict quality inspections, including dimensional accuracy inspections and weld strength inspections. Through slots are reserved on the steel frame, and the dimensional accuracy of the through slots is controlled within a very small tolerance range to ensure that it can be accurately docked with bases of different specifications. After that, holes are accurately opened at the bottom of the quartz countertop according to the pre-designed positions, and the diameter and depth of the holes match the selected M10 chemical anchor bolts. The steel is installed at the bottom of the quartz countertop by bolts. The specific operations are as follows: First, determine the installation position of the anchor bolts at the bottom of the quartz countertop and on the steel frame, and mark them. This step requires the use of high-precision measuring tools, such as calipers and positioning templates, to ensure accurate positioning so that the steel frame can fit tightly with the quartz countertop, and the gap between the two is controlled within 0.5mm. Then use an electric drill to drill holes at the marked positions according to the specifications of the anchor bolts. The speed and feed rate of the electric drill are reasonably adjusted according to the hardness of the quartz stone to ensure the accuracy and quality of the drilling. The anchor bolts use M10 chemical anchor bolts, and the drilling depth needs to be maintained at 110-130mm. After the drilling is completed, use a hair dryer to clean the dust and debris in the hole. The wind force and temperature of the hair dryer have been adjusted to effectively remove dust and debris without causing thermal effects on the quartz stone. Put the chemical agent at the bottom of the hole, and use a special installation tool to slowly rotate the screw into the hole. During the insertion process, the operator will operate at a uniform speed and force to evenly distribute the chemical agent between the screw and the hole wall to ensure that the anchoring effect of the chemical anchor bolt is optimal. Finally, align the mounting holes of the steel frame with the inserted screws, and then use nuts and washers to fix the steel frame to the bottom of the quartz countertop. When tightening the nuts, operate according to the specified torque value. Generally, the torque value is set between 40-50N·m, which can effectively ensure the fastening between the steel frame and the quartz countertop, making the entire countertop structure stable and reliable.

[0022] During the coating treatment stage, advanced HVLP spray guns are used for spraying primer, wear-resistant paint and stone protective agent. Before spraying the primer, the spray gun is thoroughly cleaned and debugged to ensure that the air pressure of the spray gun is stable and the nozzle is not blocked. The air pressure is set at 2-3bar. This air pressure range is the best value determined after many tests, which can make the primer spray in a uniform atomized state. The nozzle size is 1.3-1.5mm. This size of nozzle can adapt to the viscosity and spraying requirements of epoxy primer. Pour the epoxy primer into the container of the spray gun, start the spray gun, and spray at a height of 30-50cm from the countertop. The operator will stand in a suitable position, start from one end of the countertop, and move the spray gun at a uniform speed. The moving speed is controlled at about 30-40 cm per second, so that the paint mist falls evenly on the countertop. When spraying the primer, the strokes of each spray should overlap appropriately, and the overlap width is about one-third of the spray gun spray width to ensure complete coverage. During the spraying process, the spray gun needs to be kept vertical to the table, and the deviation angle is controlled within ±5° to avoid uneven thickness. After the primer is sprayed, the spray gun should be thoroughly cleaned immediately. The cleaning process includes flushing the internal pipes, nozzles and other parts of the spray gun with a special solvent, and then rinsing with clean water and blowing dry to ensure that there is no residual primer in the spray gun to avoid affecting the subsequent spraying quality of the wear-resistant paint.

[0023] After cleaning, pour in epoxy wear-resistant paint and repeat the above primer spraying steps to spray the wear-resistant paint. The spraying thickness of the wear-resistant paint is generally controlled between 0.2-0.3mm, and the specified thickness is achieved through multiple sprayings. The interval between each spraying is about 4-6 hours to ensure that the previous layer of wear-resistant paint can be fully dried and cured, so that the final wear-resistant paint layer has good hardness and wear resistance.

[0024] After the wear-resistant paint is sprayed, clean the spray gun again, set the air pressure at 1.5-2bar, and pour in the fluoropolymer protective agent. Since the fluoropolymer protective agent mainly forms a protective film on the surface of the quartz stone, more attention should be paid to uniformity during spraying. The spray gun needs to be 40-60cm away from the table. The operator will be more careful to control the movement speed and spray angle of the spray gun, with a movement speed of about 20-30 cm per second, to ensure that the protective agent can be evenly covered on the surface of the quartz stone to avoid partial protection. The spray thickness of the fluoropolymer protective agent is relatively thin, generally between 0.1-0.2mm, to form a thin and dense protective film. After spraying, place the quartz countertop in a ventilated place for full drying. The ventilation environment requires good air circulation, the wind speed is maintained at about 1-2 meters per second, and the drying time is 24-48 hours. This can effectively ensure the adhesion of primer, wear-resistant paint and stone protective agent, so that each coating is closely combined to form a complete, high-performance protection system, thereby significantly improving the wear resistance of the quartz countertop, effectively resisting various scratches, and having good stain resistance.

[0025] At the final stage of assembly, glass fiber reinforced plastic is used as the adhesive material and glued to the edge of the quartz countertop. First, the glass fiber reinforced plastic is precisely cut according to the shape and size of the edge of the quartz countertop, and the cutting error is controlled between 1-2mm. Then glue is evenly applied to the edge of the quartz countertop and the adhesive surface of the glass fiber reinforced plastic. The amount of glue applied is reasonably controlled according to the area and thickness of the material. Generally, the amount applied per square meter is about 200-300 grams. After applying the glue, the glass fiber reinforced plastic is quickly pasted on the edge of the quartz countertop and compacted with a rubber roller. The hardness of the rubber roller is moderate. The operator will start from one end of the adhesive material and roll along the edge to the other end with uniform force. The rolling speed is about 10-15 cm per second to ensure that there are no bubbles or gaps between the adhesive material and the quartz countertop, and the adhesive is firmly attached. In this way, the strength of the surface corners of the quartz countertop can be effectively improved, and the wear resistance of the countertop can be further improved.

[0026] After pasting, the whole will be installed on the preset base. Align the preset base with the through slot on the steel frame at the bottom of the countertop. Before installation, the cleanliness of the through slot and the base will be checked again to ensure that there is no debris affecting the installation accuracy. Then use bolts for installation. The specifications and length of the bolts are selected according to the design requirements of the through slot and the base. When installing, first pass the bolts through the base and the through slot, then put washers on the bolts in turn and tighten the nuts. When tightening the nuts, use a torque wrench to operate according to the specified torque value. The general torque value is set between 30-40N・m to ensure that the entire countertop is installed firmly and stably to meet the needs of various usage scenarios.

[0027] The above generally describes the present invention in detail, but it is obvious to a person skilled in the art that some modifications or improvements can be made to the present invention. Therefore, modifications or improvements that do not depart from the spirit of the present invention are within the scope of protection of the present invention.

Claims

1. A process for manufacturing a countertop with high wear resistance, characterized in that: The manufacturing process of the highly wear-resistant countertop includes: material preparation, material processing, coating treatment and assembly finishing; In the material preparation stage, it is necessary to first conduct an on-site survey of the construction site, measure the required countertop dimensions, and prepare quartz stone, glue, hardware accessories, cleaning agents, primers, wear-resistant paints, stone protective agents, adhesive materials, and sandpaper; In the material processing stage, use a cutting machine to split the quartz stone until it is cut to the required size to obtain a preliminary countertop. Use a grinder to grind the cut quartz stone. Use detergent and water to clean the polished quartz stone to ensure that the surface is clean. After cleaning, wait for the quartz stone countertop to dry completely. Use steel to weld the bottom plate frame and reserve through grooves. Open holes at the bottom of the quartz stone countertop and install the steel to the bottom of the quartz stone countertop with bolts. During the coating treatment stage, use a spray gun to spray the primer, wear-resistant paint and stone protective agent. After spraying, place the quartz countertop in a ventilated place to fully dry; At the final stage of assembly, use adhesive material to stick to the edge of the quartz countertop with glue and compact it with a rubber roller. Then install the whole thing on the preset base, align the preset base with the through groove on the steel frame at the bottom of the countertop, and install it with bolts.

2. A process for manufacturing a table top with high wear resistance according to claim 1, characterized in that: The quartz countertop is ventilated for 24-48 hours during the coating treatment phase.

3. The process for manufacturing a table top with high wear resistance according to claim 1, characterized in that: During the material processing stage, the cutting and polishing of quartz stone must ensure precision. When polishing, first use 80-100 mesh coarse sandpaper to polish to remove surface cutting marks and large flaws, and then use 200 mesh, 400 mesh, 800 mesh, and 1200 mesh sandpaper in turn for fine polishing to make the countertop surface very smooth and reduce surface roughness.

4. The process for manufacturing a table top with high wear resistance according to claim 1, characterized in that: The material processing stage includes the following specific steps to connect the steel and the quartz countertop: First, determine the installation position of the anchor bolts on the bottom of the quartz countertop and the steel frame, and mark them. This step needs to ensure that the position is accurate so that the steel frame can fit tightly with the quartz countertop. Use an electric drill to drill holes at the marked locations according to the specifications of the anchor bolts; Use a hair dryer to clean the dust and debris in the borehole, put the chemical agent into the bottom of the borehole, and use a tool to slowly rotate the screw into the borehole so that the chemical agent is evenly distributed between the screw and the borehole wall; Align the mounting holes of the steel frame with the inserted screws, then use nuts and washers to fix the steel frame to the bottom of the quartz countertop and tighten the nuts.

5. A process for manufacturing a table top with high wear resistance according to claim 4, characterized in that: The anchor bolts are M10 chemical anchor bolts, and the drilling depth needs to be maintained at 110-130mm.

6. The process for manufacturing a table top with high wear resistance according to claim 1, characterized in that: The primer is epoxy primer, the wear-resistant paint is epoxy wear-resistant paint, and the stone protective agent is fluorine-containing polymer protective agent.

7. A process for manufacturing a table top with high wear resistance according to claim 6, characterized in that: The coating treatment stage of spraying primer, wear-resistant paint and stone protective agent includes the following specific steps: Use an HVLP spray gun, set the air pressure at 2-3 bar, and use a nozzle size of 1.3-1.5 mm. Pour the epoxy primer into the container of the spray gun, start the spray gun, and spray at a height of 30-50 cm from the countertop. Start from one end of the countertop and move the spray gun at a uniform speed so that the paint mist falls evenly on the countertop. After the primer is sprayed, clean the spray gun, pour in epoxy wear-resistant paint, and repeat the above steps to spray; After spraying the wear-resistant paint, clean the spray gun, set the air pressure at 1.5-2bar, pour in the fluoropolymer protective agent, and when spraying, the spray gun needs to be 40-60cm away from the table.

8. The process for manufacturing a table top with high wear resistance according to claim 7, characterized in that: When spraying the primer during the coating treatment stage, each spray should overlap appropriately to ensure complete coverage. During the spraying process, the spray gun should be kept vertical to the table to avoid uneven thickness.

9. The process for manufacturing a table top with high wear resistance according to claim 1, characterized in that: The adhesive material is glass fiber reinforced plastic.

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