Production process for preparing artificial stone with concave-convex texture by blending natural stone and polymer

Abstract

The invention discloses a production process for preparing artificial stone with concave-convex textures by blending natural stone and a polymer. The production process comprises the following steps: step 1, raw material selection and pretreatment; 2, blending and stirring the raw materials; 3, mold treatment and texture template laying; step 4, forming operation; step 5, curing process; the method has the advantages that the unique texture form of the natural stone can be accurately re-carved through the customized concave-convex texture template, the extreme pursuit of high-end building decoration and home design for natural aesthetic feeling is met, the complex, natural and smooth concave-convex texture is extremely attractive in vision, the friction force of the surface of a product is increased, and the appearance of the product is attractive. Meanwhile, various complex textures can be flexibly manufactured according to different design requirements, the personalized decoration requirements are met, the application scene in the decoration field is widened, the chemical corrosion resistance and the ageing resistance of the product are enhanced, the stable physical performance can be kept in different environments, and the maintenance cost is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of artificial stone production, and in particular to a production process for preparing artificial stone with concave-convex texture by blending natural stone and polymer. Background Art

[0002] In the field of architectural decoration and household goods, the beauty and practicality of decorative materials have always been the focus of people's attention. Natural stone has long been loved by designers and consumers for its unique texture, color and texture, and is widely used in decorative scenes such as walls, floors, countertops, etc. With the continuous development of the architectural decoration industry, people's requirements for the beauty, functionality and personalization of decorative materials are increasing. Artificial stone, as a material widely used in indoor and outdoor decoration, is highly favored because of its customizability, no radiation, rich colors and other advantages. Artificial stone is not only diverse in functions and rich in colors, but also has a wider range of applications. The surface texture of traditional artificial stone is relatively simple, mostly smooth planes or simple imitation stone pattern prints. In addition, artificial stone is widely used because of its rich colors, customizability and good physical properties.

[0003] However, existing natural stone resources are scarce and the mining cost is high. In addition, the specifications and sizes of natural stones are limited by natural ore bodies, making it difficult to meet the special size requirements of some large-scale construction projects or personalized designs. At the same time, the existing production process of concave-convex textured artificial stones has obvious shortcomings. On the one hand, the concave-convex textures prepared by some processes are stiff and unnatural, which is far from the texture and texture of natural stones and cannot meet the needs of customers with high requirements for decorative effects. On the other hand, some preparation processes are too complicated and require the use of special equipment and molds, which not only increases production costs, but also reduces production efficiency, which is not conducive to large-scale industrial production. In addition, in terms of performance, some concave-convex textured artificial stones have insufficient product strength and poor wear resistance due to raw material selection or process defects. Surface wear and texture damage are prone to problems such as surface wear and texture damage during use, which seriously affects the service life and market reputation of the product. Therefore, there is an urgent need for a production process for preparing concave-convex textured artificial stones by blending natural stone and polymer, which is used to provide consumers with a production process for preparing concave-convex textured artificial stones with natural texture, excellent performance, simple production process and controllable cost.

[0004] At present, there is an urgent need for a production process for preparing concave-convex texture artificial stone by blending natural stone and polymer, which can not only prepare natural and realistic texture, but also have good physical properties, and the production process is simple and the cost is controllable. Therefore, it is of great practical significance to develop a production process for preparing concave-convex texture artificial stone by blending natural stone and polymer. In order to solve the above problems, the present invention proposes a production process for preparing concave-convex texture artificial stone by blending natural stone and polymer. Summary of the invention

[0005] The technical problem to be solved by the present invention is to provide a production process for preparing artificial stone with concave-convex texture by blending natural stone and polymer, which can prepare artificial stone with natural and realistic texture and good physical properties, and at the same time has a simple production process and controllable cost.

[0006] In order to solve the above technical problems, the present invention is solved by the following technical solution: A production process for preparing concave-convex texture artificial stone by blending natural stone and polymer, comprising the following steps:

[0007] Step 1, raw material selection and pretreatment: select high-quality, rich-textured natural marble or granite, use jaw crusher for initial coarse crushing, crush large stones into 5-10 cm stones, and then use cone crusher for further fine crushing, and then use vibrating screen to accurately screen according to particle size, to obtain large-size particles of 5-10 mm, medium-size particles of 1-5 mm, and small-size particles less than 1 mm, and reserve them at a ratio of 30%-40%, 40%-50%, and 10%-20%. Put the screened natural stone particles into the cleaning pool, rinse with high-pressure water gun to remove the dirt, dust and impurities on the surface, and then put them in the drying equipment, dry them at 100-120℃ until the moisture content is less than 0.5%, and use unsaturated polyester resin As the main polymer, accurately weigh the required amount according to the formula, add methyl ethyl ketone peroxide initiator at 1% to 3% of the mass of the polymer and cobalt cyclohexane accelerator at 0.5% to 1.5% of the mass of the polymer to the unsaturated polyester resin, use a stirrer to stir at a low speed for 3 to 5 minutes to fully mix them, add an appropriate amount of inorganic pigment according to the target artificial stone color, turn on the high-speed stirrer, stir at a speed of 800-1000r / min for 5 to 8 minutes until the pigment is evenly dispersed in the polymer, weigh silane coupling agent at 0.5% to 1.5% of the mass of natural stone particles, add it to the polymer mixed with the pigment, continue stirring for 3 to 5 minutes, and finally add 0.1% to 0.5% of the mass of the polymer silicone defoamer and stir for 2 to 3 minutes;

[0008] Step 2, blending and stirring of raw materials: according to the preset formula ratio, use high-precision metering equipment to accurately measure the natural stone particles, polymer materials, pigment slurry and additives, and add the pre-treated natural stone particles of different particle sizes into a high-speed mixer equipped with special stirring blades in turn. First, stir at a low speed for 3 to 5 minutes, and control the stirring speed at 200-400r / min to allow the stone particles to be initially mixed. Then increase the stirring speed to 800-1200r / min and stir at a high speed for 5 to 10 minutes to fully blend the natural stone particles and the polymer containing additives to ensure that each stone particle is evenly coated with the polymer;

[0009] Step 3, mold processing and texture template laying: select a mold whose size and shape meet the production requirements, clean the inner surface of the mold thoroughly with detergent and water to remove oil and impurities, then wipe it dry with a clean cloth, spray a layer of release agent evenly on the inner surface of the mold, ensure that the release agent covers the entire surface without any omissions, leave it for 10 to 15 minutes, let the release agent fully dry and form a film, carefully lay the silicone or rubber concave and convex texture template of the flexible template customized according to the design requirements on the inner surface of the mold, start from one end of the mold, slowly fit the template to the mold, and use a scraper or roller to gently squeeze from the center of the template to the edge, expel the air between the template and the mold, make the template fit tightly to the mold, and ensure that the texture is clear and there are no wrinkles;

[0010] Step 4, molding operation: slowly pour the blended material into the mold with the texture template, and use the layered filling method to first pour one-third of the mold height and compact it appropriately with tools; then pour one-third and compact it again; finally fill the mold to ensure that the material is evenly distributed without obvious gaps and accumulation. Place the mold filled with materials on the vibration table, turn on the vibration table, set the vibration frequency to 30-50Hz and the amplitude to 0.5-1.5mm, and vibrate for 3 to 5 minutes to fully discharge the bubbles in the material and make the material further dense. During the vibration process, observe the surface of the material at any time. If bubbles emerge, eliminate them with tools in time. For some products with higher requirements for internal structure, vacuum-assisted molding can be used. Put the mold after vibration exhaust into the vacuum box, close the vacuum box door, start the vacuum pump, and draw the vacuum degree to 0.08-0.1MPa. Keep it for 5 to 10 minutes to further discharge the tiny bubbles remaining in the material and make the material more tightly combined;

[0011] Step 5, curing process: put the molded mold into the curing furnace, set the curing furnace temperature to 40-50℃, and cure for 2-3 hours. At this stage, the polymer begins to slowly cross-link and cure to form a preliminary structure. After the low-temperature curing is completed, the curing furnace temperature is increased to 50-60℃ and continued to cure for 2-5 hours. At the high temperature stage, the polymer is fully cross-linked, so that the natural stone particles and the polymer are firmly combined to form an artificial stone with a certain strength and stability;

[0012] Step 6, demoulding and post-processing: After curing is completed, take the mold out of the curing furnace and cool it naturally to room temperature. Use tools to carefully start from the edge of the mold and gently pry the gap between the mold and the molded artificial stone to gradually separate the two. Take out the artificial stone blank completely, and use the coarse-grained grinding wheel fixed on the grinder to perform preliminary grinding on the surface of the artificial stone blank to remove surface unevenness, excess materials and defects that may occur during the demoulding process. Keep the grinder moving at a constant speed during grinding to ensure uniform grinding. Use a fine-grained grinding wheel for fine grinding to further improve the surface flatness, and then use a polishing wheel and polishing paste for polishing to make the concave and convex texture clearer and the surface gloss meet the design requirements. Finally, use chemical coating or physical plating for surface treatment. According to the size requirements of the product, use cutting equipment to trim the artificial stone to ensure the size accuracy and edge neatness of the product.

[0013] Preferably, the natural stone is marble or granite, the initiator is methyl ethyl ketone peroxide, and the accelerator is cobalt cyclopentaneate.

[0014] Preferably, the amount of the initiator methyl ethyl ketone peroxide is 1% to 3% of the mass of the polymer, and the amount of the accelerator cobalt cyclohexaneate is 0.5% to 1.5% of the mass of the polymer.

[0015] Preferably, the coupling agent is a silane coupling agent, the defoaming agent is an organic silicon defoaming agent, and the molding operation includes vibration molding and vacuum molding.

[0016] Preferably, the coupling agent silane coupling agent is used in an amount of 0.5% to 1.5% of the mass of the natural stone particles, the defoaming agent silicone defoaming agent is used in an amount of poly (preferably, the polymer includes unsaturated polyester resin, epoxy resin and polymethyl methacrylate), and the flexible template material is silicone or rubber.

[0017] Preferably, during the vibration molding, the mold is placed on a vibration table for vibration operation, and the vibration frequency of the vibration equipment is 20-50 Hz and the amplitude is 0.5-2 mm.

[0018] Preferably, the chemical coating is one of an organic silicon coating and a fluorocarbon coating, and the physical coating is one of a vacuum coating and a magnetron sputtering coating.

[0019] Preferably, the auxiliary agent includes but is not limited to a promoter, a defoamer, and a coupling agent, and the inorganic filler is at least one of calcium carbonate, quartz powder, and talcum powder.

[0020] Preferably, during the vacuum forming, the mold is placed in a vacuum box for vacuum treatment, and the curing process adopts a staged heating method.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] 1. The production process of preparing concave-convex textured artificial stone by blending natural stone and polymer of the present invention can accurately reproduce the unique texture of natural stone through customized concave-convex texture templates, and can restore the delicate stone grain of marble and the rough texture of granite, satisfying the ultimate pursuit of natural beauty in high-end architectural decoration and home design, making artificial stone infinitely close to natural stone in terms of vision and touch. At the same time, the flexible characteristics of template materials such as silicone and rubber enable it to flexibly produce various complex textures according to different design requirements, and can freely give play to creativity, providing consumers with rich and diverse texture options, meeting personalized decoration needs, and broadening the application scenarios of artificial stone in the field of decoration;

[0023] 2. The production process of preparing concave-convex texture artificial stone by blending natural stone and polymer of the present invention forms a compact structure through a reasonably proportioned natural stone particles and polymer blending system. Natural stone particles of large, medium and small particle sizes fill and support each other. The polymer firmly wraps the stone particles as a binder, so that the prepared artificial stone has higher compressive strength and bending strength, can withstand greater external force impact, is not easy to deform or crack, and is suitable for application scenarios where the ground and countertops are subjected to greater pressure. At the same time, the natural stone itself has high hardness and good wear resistance. After being combined with the polymer with excellent performance, the wear resistance of the artificial stone is further improved, the wear marks in daily use are reduced, and the service life of the product is extended. The use of additives enhances the chemical corrosion resistance and anti-aging performance of the product, so that it can maintain stable physical properties in different environments and reduce maintenance costs;

[0024] 3. The production process of preparing artificial stone with concave-convex texture by blending natural stone and polymer of the present invention adopts common equipment and mature operation. From raw material preparation to product molding, each step is simple and easy to control, and does not require complicated technology and high equipment investment. It greatly shortens the production cycle and improves production efficiency. It is suitable for large-scale industrial production and can respond to market demand quickly. At the same time, raw materials such as natural stone and polymer are widely available and relatively cheap. The simple production process reduces energy consumption and equipment loss, reduces production costs, and improves the market competitiveness of products while ensuring high product quality, creating a larger profit margin for enterprises. DETAILED DESCRIPTION

[0025] Unless the context clearly dictates otherwise, unmodified nouns and nouns modified by "the" include singular and plural referents.

[0026] As used in the specification and claims, the terms "comprises," "comprising," "having," "may," "containing," and variations thereof as used herein refer to open transitional phrases, terms, or words that require the presence of specified ingredients / steps and allow for the presence of other ingredients / steps. However, such descriptions should be interpreted as also describing compositions or methods as "consisting of" and "consisting essentially of" the recited ingredients / steps, which allows for the presence of only the specified ingredients / steps and any unavoidable impurities that may result therefrom, and excludes other ingredients / steps.

[0027] Numerical values ​​in the specification and claims of this application should be understood to include the same numerical values ​​when reduced to the same number of significant figures and numerical values ​​that differ from the stated value by less than the experimental error of ordinary measurement techniques of the type described in this application for determining the stated value.

[0028] All ranges disclosed herein are inclusive of the indicated endpoints and are independently combinable (eg, the range of "2 grams to 10 grams" includes the endpoints 2 grams and 10 grams, and all intermediate values).

[0029] The terms "about" and "approximately" can be used to include any numerical value that can be varied without changing the basic function of the value. When used with a range, "about" and "approximately" also disclose the range defined by the absolute values ​​of the two endpoints, for example, "about 2 to about 4" also discloses a range of "2 to 4". Generally, the terms "about" and "approximately" can refer to ±10% of the indicated number. However, for temperature, the term "approximately" refers to ±1°C.

[0030] Unless expressly stated otherwise, the percentages of elements are to be considered as percentages by weight of the alloy in question.

[0031] The present disclosure may refer to the temperature of certain method steps. It should be noted that these specifications generally refer to the temperature set by the heat source (such as a furnace), and not necessarily the temperature that the heated material must reach.

[0032] The following description is used to disclose the present invention and enable those skilled in the art to implement the present invention. The preferred embodiments described below are only examples, and those skilled in the art may think of other obvious variations. The basic principles of the present invention defined in the following description may be used for other embodiments, variations, improvements, equivalents, and other technical solutions that do not deviate from the spirit and scope of the present invention.

[0033] Example 1

[0034] 1. Raw material preparation

[0035] 1. Natural stone: Select high-quality natural marble and crush it with professional stone crushing equipment. First use a jaw crusher for coarse crushing, then use a cone crusher for fine crushing, and finally use a vibrating screen for screening and grading. The large-size particles of 5-10mm account for 35%, the medium-size particles of 1-5mm account for 45%, and the small-size particles less than 1mm account for 20%. The screened natural marble particles are placed in a cleaning pool and rinsed with a high-pressure water gun to remove impurities on the surface. Then they are dried in a drying equipment at 110℃ until the moisture content is less than 0.5%.

[0036] 2. Polymer: Use unsaturated polyester resin as the binder, accurately weigh a certain amount of resin, add methyl ethyl ketone peroxide as the initiator at 2% of the resin mass, add cobalt cyclohexaneate as the accelerator at 1% of the resin mass, use an electric stirrer to stir at a low speed (200r / min) for 4 minutes to evenly disperse the initiator and accelerator in the resin.

[0037] 3. Additives: In order to make the artificial stone present a color similar to that of natural marble, add an appropriate amount of inorganic pigment, turn on the high-speed mixer, and stir at a speed of 900r / min for 6 minutes to ensure that the pigment is evenly dispersed. Then, add silane coupling agent according to 1% of the mass of natural marble particles and stir for 4 minutes to enhance the bonding force between stone particles and polymers. Finally, add silicone defoamer according to 0.3% of the mass of polymer and stir for 3 minutes to eliminate bubbles generated during the mixing process.

[0038] 2. Mixing and stirring

[0039] The dried natural marble particles of different particle sizes are added into the high-speed mixer in turn, and stirred at a low speed (300r / min) for 4 minutes to initially mix the stone particles. Then the stirring speed is increased to a high speed (1000r / min) and stirred for 8 minutes to fully blend the natural marble particles and the polymer containing the additive to form a uniform material system.

[0040] 3. Mold preparation

[0041] Select a rectangular steel mold with a size of 1200mm×800mm×25mm, clean the inner surface of the mold thoroughly with detergent and water to remove oil and impurities, and wipe it dry with a clean cloth, spray a layer of release agent evenly on the inner surface of the mold, leave it for 15 minutes, and wait for the release agent to fully dry and form a film. Then, start from one end of the mold and slowly lay the customized silicone concave and convex texture template with imitation natural marble stone pattern on the inner surface of the mold. At the same time, use a scraper to gently squeeze it to expel the air between the template and the mold, so that the template and the mold fit closely to ensure clear texture and no wrinkles.

[0042] 4. Molding operation

[0043] Slowly pour the blended material into the mold paved with a textured template, using a layered filling method. First, pour one-third of the mold height and compact it properly with a spatula; then pour one-third and compact it again; finally fill the mold to ensure that the material is evenly distributed without obvious gaps and accumulation. Place the mold filled with the material on a vibration table, turn on the vibration table, set the vibration frequency to 40Hz and the amplitude to 1mm, and vibrate for 4 minutes to fully expel the bubbles in the material and make the material further dense. During the vibration process, observe the surface of the material at any time. If bubbles emerge, pierce them with a needle tool in time to eliminate them.

[0044] 5. Curing process

[0045] Put the formed mold into the curing furnace, first set the curing furnace temperature to 45℃, and cure for 2.5 hours. At this stage, the polymer begins to slowly cross-link and cure to form a preliminary structure. After the low-temperature curing is completed, increase the curing furnace temperature to 55℃ and continue curing for 3.5 hours. At the high temperature stage, the polymer is fully cross-linked, so that the natural marble particles and the polymer are firmly combined to form an artificial stone with a certain strength and stability.

[0046] 6. Demolding and post-processing

[0047] After the curing is completed, the mold is taken out of the curing furnace and naturally cooled to room temperature. Use a crowbar or other tools to carefully start from the edge of the mold and gently pry the gap between the mold and the formed artificial stone to gradually separate the two and completely remove the artificial stone blank. Use a coarse-grained grinding wheel (80 mesh) fixed on the grinder to perform preliminary grinding on the surface of the artificial stone blank to remove surface unevenness, excess materials and defects that may occur during the demolding process. Keep the grinder moving at a constant speed during grinding to ensure uniform grinding. Use a fine-grained grinding wheel (200 mesh) for fine grinding to further improve the surface flatness. Then use a polishing wheel and polishing paste for polishing to make the concave and convex texture clearer and the surface glossiness reaches 80 gloss units. According to the size requirements of the product, use CNC cutting equipment to trim the artificial stone to ensure that the size accuracy of the product is controlled within ±1mm and the edge neatness meets the process requirements.

[0048] Example 2

[0049] 1. Raw material preparation

[0050] 1. Natural stone: natural granite is selected, and after crushing and screening, large-size particles of 5-10 mm are obtained, accounting for 30%, medium-size particles of 1-5 mm account for 50%, and small-size particles less than 1 mm account for 20%. The cleaning and drying methods are the same as those in Example 1.

[0051] 2. Polymer: Use epoxy resin as the binder, add a suitable initiator at 1.5% of the mass of the epoxy resin, add a promoter at 0.8%, and stir at a low speed for 5 minutes to mix evenly.

[0052] 3. Additives: Add pigments to adjust the color, add silane coupling agent at 0.8% of the mass of natural granite particles, add silicone defoamer at 0.2% of the mass of polymer, and stir evenly in sequence.

[0053] 2. Mixing and stirring

[0054] Stir at low speed (250r / min) for 3 minutes and then at high speed (900r / min) for 7 minutes to fully blend the raw materials.

[0055] 3. Mold preparation

[0056] Select a circular mold with a diameter of 800mm and a depth of 30mm. After cleaning the mold and applying a release agent, lay a rubber concave-convex texture template that imitates the texture of granite.

[0057] 4. Molding operation

[0058] After the material fills the mold, vacuum-assisted molding is used. The mold is placed in a vacuum box and evacuated to 0.09 MPa for 7 minutes to expel bubbles and allow the material to combine tightly.

[0059] 5. Curing process

[0060] The curing temperature was maintained at 50°C and the curing time was 6 hours.

[0061] 6. Demolding and post-processing

[0062] After cooling and demoulding, use a 100-mesh grinding wheel for rough grinding and a 250-mesh grinding wheel for fine grinding. After polishing, use cutting equipment to trim the edges to ensure dimensional accuracy and edge quality.

[0063] Example 3

[0064] 1. Raw material preparation:

[0065] Marble is selected as natural stone and crushed into large-size particles (5-10 mm) accounting for 35%, medium-size particles (1-5 mm) accounting for 45%, and small-size particles (less than 1 mm) accounting for 20%.

[0066] Unsaturated polyester resin was selected as the polymer, and methyl ethyl ketone peroxide as an initiator (the amount used was 2% of the polymer mass) and cobalt cyclohexaneate as an accelerator (the amount used was 1% of the polymer mass) were added.

[0067] An appropriate amount of pigment is added to simulate the color of natural marble, and a silane coupling agent (the amount is 1% of the mass of the natural stone particles) and an organosilicon defoamer (the amount is 0.3% of the mass of the polymer) are added.

[0068] 2. Mixing and stirring:

[0069] Add the above raw materials into a high-speed mixer in sequence, and stir at a low speed (300 r / min) for 4 minutes to ensure that the raw materials are initially mixed evenly.

[0070] Then, the stirring speed was increased to high speed (1000 r / min) and stirred for 8 minutes to form a uniform blend.

[0071] 3. Mold preparation:

[0072] Select a rectangular mold with a size of 1000mm×600mm×20mm and apply a release agent on the mold surface.

[0073] A layer of silicone concave-convex texture template imitating natural marble is laid on the inner surface of the mold.

[0074] 4. Molding:

[0075] Pour the mixed blend into the mold so that it evenly fills the mold space and covers the concave-convex texture template.

[0076] The vibration molding method was adopted, and the mold was placed on a vibration table and vibrated for 4 minutes at a frequency of 40 Hz and an amplitude of 1 mm.

[0077] 5. Curing:

[0078] The molded mold was placed in a curing oven and cured at 45°C for 2.5 hours, then heated to 55°C for another 3.5 hours.

[0079] 6. Demolding and post-processing:

[0080] After curing is completed, the mold is taken out of the curing oven and demoulded after naturally cooling to room temperature.

[0081] The artificial stone blank is subjected to post-processing procedures such as grinding, polishing, and trimming to obtain an artificial stone product with a smooth surface and realistic concave and convex stone patterns.

[0082] Example 4

[0083] 1. Raw material preparation:

[0084] Granite is selected as the natural stone, with large-size particles (5-10mm) accounting for 30%, medium-size particles (1-5mm) accounting for 50%, and small-size particles (less than 1mm) accounting for 20%.

[0085] The polymer is epoxy resin, the amount of initiator (appropriate type) is 1.5% of the mass of the polymer, and the amount of accelerator (appropriate type) is 0.8% of the mass of the polymer.

[0086] The corresponding pigment, silane coupling agent (the amount is 0.8% of the mass of the natural stone particles) and organosilicon defoamer (the amount is 0.2% of the mass of the polymer) are added.

[0087] 2. Mixing and stirring:

[0088] Stir at low speed (250r / min) for 3 minutes and at high speed (900r / min) for 7 minutes.

[0089] 3. Mold preparation:

[0090] Round mold, apply release agent, and lay rubber convex and concave texture template imitating granite texture.

[0091] 4. Molding:

[0092] After pouring the material, vacuum forming is adopted and the vacuum degree is maintained at 0.09MPa for 7 minutes.

[0093] 5. Curing:

[0094] The curing temperature is 50°C and the curing time is 6 hours.

[0095] 6. Demolding and post-processing:

[0096] After cooling and demoulding, grinding, polishing and other treatments are carried out to obtain a granite-like artificial stone product with a concave and convex texture.

[0097] Embodiment 5: A production process for preparing artificial stone with concave-convex texture by blending natural stone and polymer, comprising the following steps:

[0098] Step 1: Raw material selection and pretreatment:

[0099] Select natural marble or granite with excellent quality and rich texture, use jaw crusher for primary coarse crushing, crush large stones into 5-10 cm stones, and then use cone crusher for further fine crushing, and then use vibrating screen for accurate screening according to particle size to obtain large-size particles of 5-10 mm, medium-size particles of 1-5 mm and small-size particles less than 1 mm, and reserve them at a ratio of 30%-40%, 40%-50%, and 10%-20%. Put the screened natural stone particles into the cleaning pool, rinse with high-pressure water gun to remove impurities such as dirt and dust on the surface, and then put them into drying equipment and dry them at 100-120℃ until the moisture content is less than 0.5%. Unsaturated polyester resin is used as the main polymer , accurately weigh the required amount according to the formula, add methyl ethyl ketone peroxide initiator at 1% to 3% of the mass of the polymer and cobalt cyclohexane accelerator at 0.5% to 1.5% of the mass of the polymer to the unsaturated polyester resin, use a stirrer to stir at low speed for 3 to 5 minutes to fully mix them, add an appropriate amount of inorganic pigment according to the target artificial stone color, turn on the high-speed stirrer, stir at a speed of 800-1000r / min for 5 to 8 minutes until the pigment is evenly dispersed in the polymer, weigh silane coupling agent at 0.5% to 1.5% of the mass of natural stone particles, add it to the polymer mixed with the pigment, continue stirring for 3 to 5 minutes, and finally add 0.1% to 0.5% of the mass of the polymer silicone defoamer and stir for 2 to 3 minutes;

[0100] Step 2: Blending and stirring of raw materials:

[0101] According to the preset formula ratio, high-precision metering equipment is used to accurately measure natural stone particles, polymer materials, pigment slurry and additives. The pre-treated natural stone particles of different particle sizes are added to the high-speed mixer equipped with special stirring blades in sequence. First, stir at a low speed for 3 to 5 minutes, and the stirring speed is controlled at 200-400r / min to allow the stone particles to be initially mixed. Then, the stirring speed is increased to 800-1200r / min, and high-speed stirring is performed for 5 to 10 minutes to fully blend the natural stone particles and the polymer containing additives to ensure that each stone particle is evenly coated with the polymer.

[0102] Step 3: Mould processing and texture template laying:

[0103] Select a mold whose size and shape meet the production requirements, clean the inner surface of the mold thoroughly with detergent and water to remove oil and impurities, then wipe it dry with a clean cloth, spray a layer of release agent evenly on the inner surface of the mold, ensure that the release agent covers the entire surface without any omissions, and leave it for 10 to 15 minutes to allow the release agent to fully dry and form a film, carefully lay the silicone or rubber concave and convex texture template of the flexible template customized according to the design requirements on the inner surface of the mold, start from one end of the mold, and slowly fit the template to the mold, while using a scraper or roller to gently squeeze from the center of the template to the edge to expel the air between the template and the mold, so that the template and the mold fit tightly, ensuring clear texture and no wrinkles;

[0104] Step 4: Molding operation:

[0105] Slowly pour the blended material into the mold with the texture template, and use the layered filling method to first pour one-third of the mold height and compact it appropriately with tools; then pour one-third and compact it again; finally fill the mold to ensure that the material is evenly distributed without obvious gaps and accumulation. Place the mold filled with materials on the vibration table, turn on the vibration table, set the vibration frequency to 30-50Hz and the amplitude to 0.5-1.5mm, and vibrate for 3-5 minutes to fully discharge the bubbles in the material and make the material more dense. During the vibration process, observe the surface of the material at any time. If bubbles emerge, eliminate them with tools in time. For some products with higher requirements for internal structure, vacuum-assisted molding can be used. Put the mold after vibration exhaust into the vacuum box, close the vacuum box door, start the vacuum pump, and draw the vacuum degree to 0.08-0.1MPa. Keep it for 5-10 minutes to further discharge the tiny bubbles remaining in the material and make the material more tightly combined.

[0106] Step 5: Curing process:

[0107] Put the molded mold into the curing furnace, set the curing furnace temperature to 40-50℃, and cure for 2-3 hours. At this stage, the polymer begins to slowly cross-link and cure to form a preliminary structure. After the low-temperature curing is completed, increase the curing furnace temperature to 50-60℃ and continue to cure for 2-5 hours. At the high-temperature stage, the polymer is fully cross-linked, so that the natural stone particles and the polymer are firmly combined to form an artificial stone with a certain strength and stability.

[0108] Step 6: Demolding and post-processing:

[0109] After the curing is completed, the mold is taken out of the curing furnace and naturally cooled to room temperature. Use tools to carefully start from the edge of the mold and gently pry the gap between the mold and the formed artificial stone to gradually separate the two, and completely remove the artificial stone blank. Use a coarse-grained grinding wheel fixed on the grinder to perform preliminary grinding on the surface of the artificial stone blank to remove surface unevenness, excess materials and defects that may occur during the demolding process. Keep the grinder moving at a constant speed during grinding to ensure uniform grinding. Use a fine-grained grinding wheel for fine grinding to further improve the surface flatness, and then use a polishing wheel and polishing paste for polishing to make the concave and convex texture clearer and the surface gloss meet the design requirements. Finally, use chemical coating or physical plating for surface treatment. According to the size requirements of the product, use cutting equipment to trim the artificial stone to ensure the dimensional accuracy and edge neatness of the product.

[0110] The specific steps are as follows: the staff first selects natural marble or granite with excellent quality and rich texture, uses a jaw crusher for initial coarse crushing, breaks large pieces of stone into 5-10 cm stones, and then uses a cone crusher for further fine crushing. Subsequently, a vibrating screen is used for precise screening according to the particle size to obtain large-size particles of 5-10 mm, medium-size particles of 1-5 mm, and small-size particles of less than 1 mm, and reserve them at a ratio of 30% to 40%, 40% to 50%, and 10% to 20%. The screened natural stone particles are placed in a cleaning pool, rinsed with a high-pressure water gun to remove impurities such as dirt and dust on the surface, and then placed in a drying device and dried at 100-120°C until the moisture content is less than 0.5% , take unsaturated polyester resin as the main polymer, accurately weigh the required amount according to the formula, add methyl ethyl ketone peroxide initiator at 1% to 3% of the polymer mass and cobalt cyclohexane accelerator at 0.5% to 1.5% of the polymer mass to the unsaturated polyester resin, use a stirrer to stir at low speed for 3 to 5 minutes to make it fully mixed, add an appropriate amount of inorganic pigment according to the target artificial stone color, turn on the high-speed stirrer, stir at a speed of 800-1000r / min for 5 to 8 minutes until the pigment is evenly dispersed in the polymer, weigh silane coupling agent at 0.5% to 1.5% of the mass of natural stone particles, add it to the polymer mixed with pigment, continue stirring for 3 to 5 minutes, and finally add 0.1% to 0.5% silicone defoamer, stir for 2 to 3 minutes. At this time, the staff uses high-precision metering equipment to accurately measure the natural stone particles, polymer materials, pigment slurry and additives according to the pre-set formula ratio, and adds the pre-treated natural stone particles of different particle sizes into the high-speed mixer equipped with special stirring blades. First, stir at a low speed for 3 to 5 minutes, and control the stirring speed at 200-400r / min to allow the stone particles to be initially mixed. Then increase the stirring speed to 800-1200r / min and stir at high speed for 5 to 1 0 minutes, so that the natural stone particles and the polymer containing additives are fully blended to ensure that each stone particle is evenly coated with the polymer. At this time, the staff selects a mold whose size and shape meet the production requirements, thoroughly cleans the inner surface of the mold with detergent and water to remove oil and impurities, and then wipes it dry with a clean cloth. Spray a layer of release agent evenly on the inner surface of the mold to ensure that the release agent covers the entire surface without omissions. Leave it for 10 to 15 minutes to allow the release agent to fully dry and form a film. The silicone or rubber concave and convex texture template of the flexible template will be customized according to the design requirements. Carefully Lay it on the inner surface of the mold, starting from one end of the mold, slowly fit the template to the mold, and use a scraper or roller to gently squeeze from the center of the template to the edge to expel the air between the template and the mold, so that the template and the mold fit tightly, ensuring that the texture is clear and there are no wrinkles. At this time, the staff slowly pours the blended material into the mold paved with the texture template, using a layered filling method, first pouring one-third of the mold height, and compacting it appropriately with a tool; then pouring another one-third, compacting it again; finally filling the mold to ensure that the material is evenly distributed without obvious gaps and piles Place the mold filled with materials on the vibration table, turn on the vibration table, set the vibration frequency to 30-50Hz, the amplitude to 0.5-1.5mm, and vibrate for 3-5 minutes to fully discharge the bubbles in the material and make the material more dense. During the vibration process, observe the surface of the material at any time. If bubbles emerge, eliminate them with tools in time. For some products with higher requirements for internal structure, vacuum assisted molding can be used. Put the mold after vibration exhaust into the vacuum box, close the vacuum box door, start the vacuum pump, and draw the vacuum degree to 0.08-0.1MPa, maintain for 5 to 10 minutes, further discharge the tiny bubbles remaining in the material, so that the material is more tightly combined. At this time, the staff puts the formed mold into the curing oven, sets the curing oven temperature to 40-50℃, and cures for 2-3 hours. At this stage, the polymer begins to slowly cross-link and cure to form a preliminary structure. After the low-temperature curing is completed, the curing oven temperature is increased to 50-60℃ and continues to cure for 2-5 hours. In the high-temperature stage, the polymer is fully cross-linked, so that the natural stone particles and the polymer are firmly combined to form an artificial stone with a certain strength and stability. Finally, after the curing is completed, the staff takes the mold out of the curing oven, cools it naturally to room temperature, and carefully pries the mold from the edge of the mold with tools. The gap between the molded artificial stone and the molded artificial stone is gradually separated, and the artificial stone blank is completely taken out. The surface of the artificial stone blank is initially polished using a coarse-grained grinding wheel fixed on the grinder to remove surface unevenness, excess materials, and defects that may occur during demolding. The grinder is kept moving at a constant speed during grinding to ensure uniform grinding. Fine-grained grinding wheels are used for fine grinding to further improve surface flatness. Polishing wheels and polishing paste are then used for polishing to make the concave and convex textures clearer and the surface glossiness meets the design requirements. Finally, chemical coating or physical plating is used for surface treatment. According to the size requirements of the product, cutting equipment is used to trim the artificial stone to ensure the size accuracy and edge neatness of the product. .

[0111] It should be understood by those skilled in the art that the embodiments of the present invention shown in the above description are only examples and do not limit the present invention. The purpose of the present invention has been fully and effectively achieved. The functions and structural principles of the present invention have been demonstrated and explained in the embodiments. Without departing from the principles, the embodiments of the present invention may have any deformation or modification. Although the embodiments of the present invention have been shown and described, it is understood by those of ordinary skill in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the attached claims and their equivalents. This specific embodiment is only an explanation of the present application, and it is not a limitation of the present application. After reading this specification, those skilled in the art can make modifications to the present embodiment without creative contribution as needed, but as long as they are within the scope of the claims of the present application, they are protected by the patent law.

Claims

1. A production process for preparing artificial stone with concave-convex texture by blending natural stone and polymer, characterized in that: The following steps are involved: Step 1, raw material selection and pretreatment: select high-quality, rich-textured natural marble or granite, use jaw crusher for initial coarse crushing, crush large stones into 5-10 cm stones, and then use cone crusher for further fine crushing, and then use vibrating screen to accurately screen according to particle size, to obtain large-size particles of 5-10 mm, medium-size particles of 1-5 mm, and small-size particles less than 1 mm, and reserve them at a ratio of 30%-40%, 40%-50%, and 10%-20%. Put the screened natural stone particles into the cleaning pool, rinse with high-pressure water gun to remove the dirt, dust and impurities on the surface, and then put them in the drying equipment, dry them at 100-120℃ until the moisture content is less than 0.5%, and use unsaturated polyester resin As the main polymer, accurately weigh the required amount according to the formula, add methyl ethyl ketone peroxide initiator at 1% to 3% of the mass of the polymer and cobalt cyclohexane accelerator at 0.5% to 1.5% of the mass of the polymer to the unsaturated polyester resin, use a stirrer to stir at a low speed for 3 to 5 minutes to fully mix them, add an appropriate amount of inorganic pigment according to the target artificial stone color, turn on the high-speed stirrer, stir at a speed of 800-1000r / min for 5 to 8 minutes until the pigment is evenly dispersed in the polymer, weigh silane coupling agent at 0.5% to 1.5% of the mass of natural stone particles, add it to the polymer mixed with the pigment, continue stirring for 3 to 5 minutes, and finally add 0.1% to 0.5% of the mass of the polymer silicone defoamer and stir for 2 to 3 minutes; Step 2, blending and stirring of raw materials: according to the preset formula ratio, use high-precision metering equipment to accurately measure the natural stone particles, polymer materials, pigment slurry and additives, and add the pre-treated natural stone particles of different particle sizes into a high-speed mixer equipped with special stirring blades in turn. First, stir at a low speed for 3 to 5 minutes, and control the stirring speed at 200-400r / min to allow the stone particles to be initially mixed. Then increase the stirring speed to 800-1200r / min and stir at a high speed for 5 to 10 minutes to fully blend the natural stone particles and the polymer containing additives to ensure that each stone particle is evenly coated with the polymer; Step 3, mold processing and texture template laying: select a mold whose size and shape meet the production requirements, clean the inner surface of the mold thoroughly with detergent and water to remove oil and impurities, then wipe it dry with a clean cloth, spray a layer of release agent evenly on the inner surface of the mold, ensure that the release agent covers the entire surface without any omissions, leave it for 10 to 15 minutes, let the release agent fully dry and form a film, carefully lay the silicone or rubber concave and convex texture template of the flexible template customized according to the design requirements on the inner surface of the mold, start from one end of the mold, slowly fit the template to the mold, and use a scraper or roller to gently squeeze from the center of the template to the edge, expel the air between the template and the mold, make the template fit tightly to the mold, and ensure that the texture is clear and there are no wrinkles; Step 4, molding operation: slowly pour the blended material into the mold with the texture template, and use the layered filling method to first pour one-third of the mold height and compact it appropriately with tools; then pour one-third and compact it again; finally fill the mold to ensure that the material is evenly distributed without obvious gaps and accumulation. Place the mold filled with materials on the vibration table, turn on the vibration table, set the vibration frequency to 30-50Hz and the amplitude to 0.5-1.5mm, and vibrate for 3 to 5 minutes to fully discharge the bubbles in the material and make the material further dense. During the vibration process, observe the surface of the material at any time. If bubbles emerge, eliminate them with tools in time. For some products with higher requirements for internal structure, vacuum-assisted molding can be used. Put the mold after vibration exhaust into the vacuum box, close the vacuum box door, start the vacuum pump, and draw the vacuum degree to 0.08-0.1MPa. Keep it for 5 to 10 minutes to further discharge the tiny bubbles remaining in the material and make the material more tightly combined; Step 5, curing process: put the molded mold into the curing furnace, set the curing furnace temperature to 40-50℃, and cure for 2-3 hours. At this stage, the polymer begins to slowly cross-link and cure to form a preliminary structure. After the low-temperature curing is completed, the curing furnace temperature is increased to 50-60℃ and continued to cure for 2-5 hours. At the high temperature stage, the polymer is fully cross-linked, so that the natural stone particles and the polymer are firmly combined to form an artificial stone with a certain strength and stability; Step 6, demoulding and post-processing: After curing is completed, take the mold out of the curing furnace and cool it naturally to room temperature. Use tools to carefully start from the edge of the mold and gently pry the gap between the mold and the molded artificial stone to gradually separate the two. Take out the artificial stone blank completely, and use the coarse-grained grinding wheel fixed on the grinder to perform preliminary grinding on the surface of the artificial stone blank to remove surface unevenness, excess materials and defects that may occur during the demoulding process. Keep the grinder moving at a constant speed during grinding to ensure uniform grinding. Use a fine-grained grinding wheel for fine grinding to further improve the surface flatness, and then use a polishing wheel and polishing paste for polishing to make the concave and convex texture clearer and the surface gloss meet the design requirements. Finally, use chemical coating or physical plating for surface treatment. According to the size requirements of the product, use cutting equipment to trim the artificial stone to ensure the size accuracy and edge neatness of the product.

2. The production process for preparing artificial stone with concave-convex texture by blending natural stone and polymer according to claim 1, characterized in that: The natural stone is marble or granite, the initiator is methyl ethyl ketone peroxide, and the accelerator is cobalt cyclohexaneate.

3. The production process for preparing artificial stone with concave-convex texture by blending natural stone and polymer according to claim 1, characterized in that: The dosage of the initiator methyl ethyl ketone peroxide is 1% to 3% of the mass of the polymer, and the dosage of the accelerator cobalt cyclohexaneate is 0.5% to 1.5% of the mass of the polymer.

4. The production process for preparing artificial stone with concave-convex texture by blending natural stone and polymer according to claim 1, characterized in that: The coupling agent is a silane coupling agent, the defoaming agent is an organic silicon defoaming agent, and the molding operation includes vibration molding and vacuum molding.

5. The production process for preparing artificial stone with concave-convex texture by blending natural stone and polymer according to claim 1, characterized in that: The amount of the coupling agent silane coupling agent is 0.5% to 1.5% of the mass of the natural stone particles, and the amount of the defoaming agent organic silicon defoaming agent is 0.1% to 0.5% of the mass of the polymer.

6. The production process for preparing artificial stone with concave-convex texture by blending natural stone and polymer according to claim 1, characterized in that: The polymer includes unsaturated polyester resin, epoxy resin and polymethyl methacrylate, and the flexible template material is silica gel or rubber.

7. The production process for preparing artificial stone with concave-convex texture by blending natural stone and polymer according to claim 1, characterized in that: During the vibration molding, the mold is placed on a vibration table for vibration operation, and the vibration frequency of the vibration equipment is 20-50 Hz and the amplitude is 0.5-2 mm.

8. The production process for preparing artificial stone with concave-convex texture by blending natural stone and polymer according to claim 1, characterized in that: The chemical coating is one of an organic silicon coating and a fluorocarbon coating, and the physical coating is one of a vacuum coating and a magnetron sputtering coating.

9. The production process for preparing artificial stone with concave-convex texture by blending natural stone and polymer according to claim 1, characterized in that: The auxiliary agent includes but is not limited to a promoter, a defoamer, and a coupling agent. The inorganic filler is at least one of calcium carbonate, quartz powder, and talcum powder.

10. The production process for preparing artificial stone with concave-convex texture by blending natural stone and polymer according to claim 1, characterized in that: During the vacuum forming, the mold is placed in a vacuum box for vacuum treatment, and the curing process adopts a staged heating method.