Quartz stone product and preparation method thereof

Abstract

The invention relates to a quartz stone product and a preparation method thereof. The preparation method of the quartz stone product comprises the following steps: heating the quartz sand and the inorganic pigment at 700-1000 DEG C to obtain colored quartz sand; mixing the colored quartz sand with hydrolysate of a silane coupling agent and / or silica sol, and drying to obtain modified quartz sand; mixing the modified quartz sand with resin to obtain slurry; and molding the slurry to prepare the quartz stone product. The preparation method of the quartzite product is beneficial to improving the coloring effect of the quartzite product, and the quartzite product is not prone to fading in the cold and hot impact process.

Description

Technical Field

[0001] The present application relates to the field of kitchen and bathroom, and in particular to a quartz stone product and a preparation method thereof. Background Art

[0002] Quartz products are mainly composed of 70% or more of quartz sand, resin and additives. Quartz sand as aggregate gives the product hardness and wear resistance, while resin increases its flexibility and impact resistance. Additives such as colorants give the product a certain appearance color. Among them, quartz sinks have the advantages of wear resistance, scratch resistance, high temperature resistance, corrosion resistance, and low water absorption. At the same time, its non-porous surface structure makes it difficult for bacteria to attach, easy to clean and maintain, and is widely welcomed in the decoration of kitchens and bathrooms. The preparation of quartz sinks usually includes mixing, curing, polishing and other steps. During the mixing process, quartz sand, resin and additives are mixed under vacuum conditions to ensure that the material is uniform and free of bubbles.

[0003] However, the current quartz products such as quartz sinks still have the problem that the coloring effect needs to be improved. Summary of the invention

[0004] Based on this, the present application provides a method for preparing quartz stone products, which is beneficial to improving the coloring effect and is not easy to fade during hot and cold shock.

[0005] In addition, the present application also provides a quartz stone product on the other hand.

[0006] A method for preparing a quartz stone product comprises the following steps:

[0007] The quartz sand and the inorganic colorant are heated at 700°C to 1000°C to obtain colored quartz sand;

[0008] The colored quartz sand is mixed with the hydrolyzate of the silane coupling agent and / or silica sol, and dried to obtain modified quartz sand;

[0009] Mixing the modified quartz sand with resin to obtain slurry;

[0010] The slurry is shaped to prepare a quartz stone product.

[0011] Optionally, in the step of heating the quartz sand and the inorganic colorant at 700° C. to 1000° C., the heating time is ≥ 30 min.

[0012] Optionally, before the step of heating quartz sand, inorganic colorants and additives at 700°C~1000°C, the heating rate is set to 3°C / min~4°C / min during the heating process from 500°C to 600°C, and the heating rate is set to 3°C / min~5°C / min during the heating process from 600°C to the target temperature, and the target temperature is 700°C~1000°C.

[0013] Optionally, in the step of heating quartz sand and inorganic colorant at 700°C~1000°C, an auxiliary agent is also added, wherein the auxiliary agent includes nano alumina. Based on the total mass percentage of quartz sand, inorganic colorant and auxiliary agent as 100%, the mass percentage of quartz sand is 90%~95%, the mass percentage of inorganic colorant is 3%~5%, and the mass percentage of auxiliary agent is 1%~5%.

[0014] Optionally, the auxiliary agent further includes magnesium oxide.

[0015] Optionally, the quartz sand is non-angular quartz sand.

[0016] Optionally, the quartz sand is subjected to air flow milling treatment to obtain quartz sand without edges and corners.

[0017] Optionally, the quartz sand includes, by mass%, 5% to 10% of 20-40 mesh quartz sand, 20% to 30% of 40-60 mesh quartz sand, 25% to 35% of 60-80 mesh quartz sand, 15% to 25% of 80-100 mesh quartz sand and 5% to 15% of 100-120 mesh quartz sand.

[0018] Optionally, the mass of the hydrolyzate of the silane coupling agent and the silica sol are respectively 1% to 2% of the mass of the colored quartz sand.

[0019] Optionally, the step of preparing the hydrolyzate of the silane coupling agent comprises: mixing the silane coupling agent with an ethanol aqueous solution with a pH of 4.5 to 5.5 and hydrolyzing for 5 to 8 minutes, wherein the mass of the silane coupling agent accounts for 2% to 5% of the mass of the ethanol aqueous solution.

[0020] Optionally, in the drying step, the temperature is 80° C. to 100° C. and the time is 1 h to 2 h.

[0021] Optionally, taking the total mass percentage of the modified quartz sand and the resin as 100%, the mass percentage of the modified quartz sand is 75% to 80%, and the mass percentage of the resin is 20% to 25%.

[0022] Optionally, a curing agent is further added to the slurry, and the mass of the curing agent accounts for 0.8% to 1.5% of the mass of the resin.

[0023] Optionally, additives are further added to the slurry, the mass of the additives accounting for 1% to 5% of the total mass of the modified quartz sand and the resin, and the additives include one or more of polytetrafluoroethylene wax powder, glass flakes and fumed silica powder.

[0024] Optionally, the slurry includes an initial slurry and a reinforcing slurry, wherein the initial slurry is obtained by mixing the modified quartz sand, the resin and the curing agent, and the reinforcing slurry is obtained by mixing part of the initial slurry with the additive;

[0025] In the step of molding the slurry, the mold is turned upside down, and the reinforcing slurry and the remaining initial slurry are added to the mold in sequence, and heated and cured to form the mold.

[0026] Optionally, the mass percentage of the part of the initial slurry to the whole of the initial slurry is 8% to 10%.

[0027] Optionally, in the step of heating and curing, the temperature is increased to 80°C to 100°C at a heating rate of 1°C / min to 4°C / min and kept at this temperature for 1.5h to 2h.

[0028] A quartz stone product is prepared by the above preparation method.

[0029] Optionally, the quartz stone product is a quartz stone sink.

[0030] The preparation method of traditional quartz products is mostly to mix quartz sand, colorant and resin to obtain slurry, shape the slurry and prepare quartz products. However, the quartz products prepared by this method still have the problem that the coloring ability needs to be improved. Based on this, some embodiments of the present application provide a preparation method of quartz products, wherein quartz sand and inorganic colorant are heated at 700°C to 1000°C, and then the colored quartz sand is mixed with the hydrolyzate and / or silica sol of the silane coupling agent and dried to obtain modified quartz sand, which is then mixed with the resin and molded. The quartz sand and inorganic colorant are mixed by high temperature heating, which is more conducive to improving the coloring effect of the inorganic colorant than the method of directly mixing with the resin at room temperature, so that it is not easy to fade during the process of cold and hot shock. In addition, mixing the colored quartz sand with the hydrolyzate and / or silica sol of the silane coupling agent, drying, and then mixing with the resin is conducive to improving the compatibility, adhesion and mixing uniformity of the quartz sand and the resin, so that the prepared quartz products have a uniform appearance and are not easy to fade during the process of cold and hot shock.

[0031] Therefore, the preparation method of the quartz stone products in some embodiments of the present application is conducive to improving the coloring effect thereof. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0033] Figure 1 A schematic diagram of a process flow of a method for preparing quartz stone products according to some embodiments of the present application;

[0034] Figure 2 This is a macroscopic picture of the non-angular quartz sand after the air flow milling treatment in Example 1 of the present application;

[0035] Figure 3 This is a macroscopic enlarged picture of ordinary quartz sand that has not been treated with jet milling;

[0036] Figure 4 This is a physical picture of the quartz stone water tank prepared in Example 1 of the present application. DETAILED DESCRIPTION

[0037] In order to facilitate the understanding of the present application, the present application will be described more comprehensively below in conjunction with the specific embodiments. The preferred embodiments of the present application are provided in the specific embodiments. However, the present application can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the understanding of the disclosure of the present application more thorough and comprehensive.

[0038] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those generally understood by those skilled in the art to which the present application belongs. The terms used herein in the specification of the present application are only for the purpose of describing specific embodiments and are not intended to limit the present application. The term "and / or" used herein includes any and all combinations of one or more related listed items.

[0039] Unless otherwise specified or there is a contradiction, the terms and phrases used in this application have the following meanings:

[0040] In this application, "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of the features.

[0041] In the description of the present application, “plurality” means at least two, for example, two, three, etc., unless otherwise clearly and specifically defined.

[0042] In this application, "one or several" refers to any one, any two or more of the listed items. Among them, "several" refers to any two or more of the listed items.

[0043] In this application, the percentage concentration involved, unless otherwise specified, refers to the final concentration. The final concentration refers to the proportion of the added component in the system after the addition of the component.

[0044] In this document, "further", "further", "particularly", "for example", "such as", "example", "for example", etc. are used for descriptive purposes, indicating that the previous and subsequent technical solutions are related in terms of the content covered, but should not be understood as a limitation on the previous technical solution, nor can it be understood as a limitation on the protection scope of this document. In this document, unless otherwise specified, A (such as B) means that B is a non-limiting example of A, and it can be understood that A is not limited to B.

[0045] Herein, "optionally", "optional", and "optional" mean optional, that is, any one of the two parallel schemes of "yes" or "no". If multiple "optional" items appear in a technical solution, unless otherwise specified and there is no contradiction or mutual restriction, each "optional" item is independent of each other. In this application, descriptions such as "optionally contain", "optionally include", etc. mean "contain or not contain". "Optional component X" means that component X exists or does not exist, or means that component X is contained or not contained.

[0046] When a numerical range is disclosed in this application, the above range is considered to be continuous and includes the minimum and maximum values ​​of the range, as well as every value between such minimum and maximum values. Further, when a range refers to an integer, every integer between the minimum and maximum values ​​of the range is included. In addition, when multiple ranges are provided to describe features or characteristics, the ranges can be combined. In other words, unless otherwise indicated, all ranges disclosed in this application should be understood to include any and all subranges included therein.

[0047] In the present application, the technical features described in an open manner include closed technical solutions composed of the listed features, and also include open technical solutions containing the listed features.

[0048] The terms "including" and "having" and any variations thereof in the embodiments of the present application are intended to cover non-exclusive inclusions. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units that are not listed, or may optionally include other steps or components that are inherent to these processes, methods, products, or devices.

[0049] Reference to "embodiments" in this application means that a particular feature, structure, or characteristic described in conjunction with the embodiments may be included in at least one embodiment of the present application. The appearance of the phrase in various locations in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described in this application may be combined with other embodiments.

[0050] The first aspect of the present application provides a method for preparing a quartz stone product, comprising the following steps:

[0051] The quartz sand, the inorganic colorant and the additive are heated at 700°C to 1000°C to obtain colored quartz sand;

[0052] The colored quartz sand is mixed with the hydrolyzate of the silane coupling agent and / or the silica sol, and dried to obtain modified quartz sand;

[0053] Mixing modified quartz sand with resin to obtain slurry;

[0054] The slurry is molded to prepare quartz stone products.

[0055] The preparation method of the above-mentioned quartz stone products is to heat quartz sand and inorganic colorants at 700°C to 1000°C, then mix and dry the colored quartz sand with the hydrolyzate of silane coupling agent and / or silica sol to obtain modified quartz sand, and then mix and shape it with resin. The quartz sand and inorganic colorants are mixed by high-temperature heating, which is more conducive to improving the coloring effect of the inorganic colorants than directly mixing them with the resin at room temperature, so that it is not easy to fade during the process of cold and hot shock. In addition, mixing and drying the colored quartz sand with the hydrolyzate of silane coupling agent and / or silica sol, and then mixing it with the resin is conducive to improving the compatibility, adhesion and mixing uniformity of quartz sand and resin, so that the prepared quartz stone products have a uniform appearance and are not easy to fade during the process of cold and hot shock.

[0056] In some embodiments, the quartz sand includes, by weight, 5% to 10% of 20-40 mesh quartz sand, 20% to 30% of 40-60 mesh quartz sand, 25% to 35% of 60-80 mesh quartz sand, 15% to 25% of 80-100 mesh quartz sand, and 5% to 15% of 100-120 mesh quartz sand. The use of quartz sands of different grades is conducive to further improving the hardness, wear resistance and other properties of the product. Furthermore, quartz powder with a mesh number greater than 120 mesh is not used in the quartz sand. If the mesh number of the quartz sand is too large and the quartz powder is too fine, the amount of resin used will increase, the strength of the product will be reduced, and the flowability of the slurry will be affected, making the slurry thicker and the fluidity worse. It is easy to form cavities during the pouring process, which will reduce the production qualification rate.

[0057] In some embodiments, the quartz sand is non-angular quartz sand. The use of non-angular quartz sand is more conducive to further improving the hardness and wear resistance of quartz stone products than conventional quartz sand. In the present application, non-angular quartz sand refers to quartz sand particles with no edges and a smooth and rounded surface. Due to the different origins and types of quartz sand, in actual operation, the structure of the processed quartz sand is visually observed with a magnifying glass to determine whether non-angular quartz sand is obtained. In one example, the angular coefficient of the non-angular quartz sand is ≤1.45.

[0058] Specifically, in some of the embodiments, quartz sand is treated by air jet milling to obtain quartz sand without edges and corners. In one specific example, quartz sands of 20 mesh, 40 mesh, 60 mesh, and 80 mesh are treated by air jet milling until the edges and corners of the quartz sand disappear, and then sieved through 40 mesh, 60 mesh, 80 mesh, 100 mesh, and 120 mesh sieves. Quartz powder with a mesh number greater than 120 mesh is not used, and other quartz sands are used after grading.

[0059] In some embodiments, the heating temperature may be, but is not limited to, 700° C., 750° C., 800° C., 850° C., 900° C., 950° C., 1000° C., or a range consisting of any two of these values. If the heating temperature is too high, such as greater than 1000° C., the inorganic colorant may be easily discolored. If the heating temperature is too low, such as less than 700° C., the coloring effect of the inorganic colorant is not good.

[0060] In some embodiments, during the process from 500°C to 600°C, the heating rate is 3°C / min to 4°C / min, during the process from 600°C to the target temperature, the heating rate is 3°C / min to 5°C / min, and the target temperature is 700°C to 1000°C. Since quartz sand undergoes a crystal transformation at 573°C, a too fast heating rate should be avoided near this temperature. The above setting can avoid cracking inside the quartz sand and improve the hardness of the product.

[0061] In some embodiments, during the process of room temperature to 500° C., the heating time is ≥ 45 min. The room temperature may be, for example but not limited to, 10° C. to 30° C., specifically, 20° C. to 25° C.

[0062] In some embodiments, the heating time is ≥ 30 min. For example, the heating time can be, but is not limited to, 30 min, 40 min, 50 min, 60 min, or a range consisting of any two of these values.

[0063] In some embodiments, in the step of heating the quartz sand and the inorganic pigment at 700°C to 1000°C, an auxiliary agent is also added, and the auxiliary agent includes nano-alumina. Nano-alumina has a large specific surface area and strong reaction activity, which can promote the adhesion of the pigment. Due to its small size effect and large surface area, nano-alumina is conducive to making the product show higher hardness, wear resistance and strength. In addition, adding nano-alumina during the heating process of quartz sand and inorganic pigment is more conducive to further improving the hardness of the product than adding nano-alumina in the subsequent mixing process with resin.

[0064] Specifically, taking the total mass percentage of quartz sand, inorganic colorant and additive as 100%, the mass percentage of quartz sand is 90%-95%, the mass percentage of inorganic colorant is 3%-5%, and the mass percentage of additive is 1%-5%.

[0065] In some embodiments, the additive further comprises magnesium oxide. Adding magnesium oxide is beneficial to improving the lubricity of the inorganic pigment. In one example, the additive comprises nano-alumina and magnesium oxide.

[0066] In some embodiments, the colored quartz sand is mixed with the hydrolyzate of the silane coupling agent and / or the silica sol, dried, and then mixed with the resin, which is beneficial to improve the compatibility, adhesion and mixing uniformity of the quartz sand and the resin, so that the prepared quartz stone product has a uniform appearance and is not easy to fade during the hot and cold shock process. At the same time, the amount of resin can be reduced, and the hardness and wear resistance of the prepared quartz stone product can be further improved. In addition, compared with the traditional method of adding a silane coupling agent during the mixing of the modified quartz sand and the resin, in some embodiments of the present application, the modified quartz sand is first mixed with the hydrolyzate of the silane coupling agent and dried, which is beneficial to further improve the compatibility, adhesion and mixing uniformity with the resin, and improve the hardness and wear resistance of the prepared quartz stone product.

[0067] Specifically, in the drying step, the temperature is 80° C. to 100° C., and the time is 1 h to 2 h.

[0068] Specifically, the mass percentage of the hydrolyzate of the silane coupling agent to the mass percentage of the modified quartz sand is 1% to 2%. The mass percentage of the silica sol to the mass percentage of the modified quartz sand is 1% to 2%.

[0069] In some embodiments, the preparation step of the hydrolyzate of the silane coupling agent includes: mixing the silane coupling agent with an ethanol aqueous solution with a pH of 4.5-5.5 and hydrolyzing for 5-8 minutes, wherein the mass of the silane coupling agent accounts for 2%-5% of the mass of the ethanol aqueous solution.

[0070] In one example, the mass percentages of ethanol and water in the ethanol aqueous solution are 95% and 5%, respectively. It can be understood that the above only provides a more specific ratio of ethanol aqueous solution, but is not limited thereto.

[0071] In one example, the silane coupling agent includes but is not limited to KH-570.

[0072] In some embodiments, the total mass percentage of modified quartz sand and resin is 100%, the mass percentage of modified quartz sand is 75% to 80%, and the mass percentage of resin is 20% to 25%. Optionally, the mass percentage of resin can be, but not limited to, 20%, 20.5%, 21%, 21.5%, 22%, 22.5%, 23%, 23.5%, 24%, 25%, or a range consisting of any two of these values. Optionally, the mass percentage of modified quartz sand can be, but not limited to, 75%, 75.5%, 76%, 76.5%, 77%, 78%, 78.5%, 79%, 80%, or a range consisting of any two of these values.

[0073] In some embodiments, the resin may be, but is not limited to, isophenylene neopentyl glycol resin.

[0074] In some embodiments, a curing agent is also added to the slurry, and the mass of the curing agent accounts for 0.8% to 1.5% of the mass of the resin. Furthermore, since the resin has certain requirements for the ambient temperature, the amount of curing agent added is slightly different in winter and summer. For example, in the preparation process of quartz stone products in the summer when the ambient temperature is high, the mass of the curing agent accounts for 0.8% to 1% of the mass of the resin; in the preparation process of quartz stone products in the winter when the ambient temperature is low, the mass of the curing agent accounts for 1% to 1.5% of the mass of the resin. It can be understood that the specific type of curing agent can be adjusted according to the type of resin, as long as it can cure the resin, and it is not particularly limited here.

[0075] In some embodiments, additives are further added to the slurry, and the mass of the additives accounts for 1% to 5% of the total mass of the modified quartz sand and the resin. The additives include one or more of polytetrafluoroethylene wax powder, glass flakes, and fumed silica powder. Adding the above additives to the slurry is conducive to further improving the hardness and wear resistance of the quartz stone products.

[0076] In some embodiments, the slurry includes an initial slurry and an enhanced slurry, wherein the initial slurry is obtained by mixing modified quartz sand, a resin and a curing agent, and the enhanced slurry is obtained by mixing part of the initial slurry with an additive;

[0077] In the step of molding the slurry, the mold is turned upside down, and the reinforcing slurry and the remaining initial slurry are added to the mold respectively, and heated and cured to form the mold.

[0078] Specifically, the mass percentage of the initial slurry is 8-10% of the total initial slurry. By mixing the initial slurry with the additive to form a reinforced slurry, the hardness and wear resistance of the product surface can be improved.

[0079] Specifically, in the step of heating and curing, the temperature is raised to 80°C to 100°C at a heating rate of 1°C / min to 4°C / min, and kept at this temperature for 1.5h to 2h.

[0080] In some of the embodiments, the mold is turned upside down, and the reinforcing slurry and the remaining initial slurry are added to the mold in sequence. Specifically, the remaining initial slurry is added after the reinforcing slurry has initially solidified. Initial solidification refers to the state in which the resin and the curing agent begin to react and form a solid after a certain period of time after being mixed. Although the mixture has gelled at this time, it has not yet reached the degree of complete solidification. The production method of the mold being turned upside down can prevent the use surface of the product from directly contacting the air. Since the curing reaction of the resin is anaerobic, if the mold is placed forward, air will enter, resulting in incomplete curing. Therefore, during production, the mold is turned upside down to ensure that the use surface of the product does not contact the air, and the reinforcing slurry is added first, and then the remaining initial slurry is added after the reinforcing slurry has initially solidified.

[0081] In one of the examples, the resin is isophthalic acid neopentyl glycol resin, and the quartz stone product is prepared in the summer. When the curing agent addition amount is 1%, the initial setting time is 14 minutes. It can be understood that in other examples, the initial setting time will be adjusted according to the ambient temperature during preparation, the curing agent addition amount, the resin type, etc.

[0082] In some embodiments, the step of molding the slurry includes: when the mold is preheated to 50°C, turning the mold upside down, adding the reinforcing slurry into the mold first, and then adding the remaining initial slurry after the reinforcing slurry is initially solidified, setting the heating rate to 1°C / min~4°C / min, heating the mold to 80°C~100°C, and keeping it warm for 1.5h~2h.

[0083] In some embodiments, before placing the slurry in the mold, a release agent is applied to the mold surface. For example, the release agent may be, but is not limited to, zinc stearate. The mold may be, but is not limited to, a glass fiber reinforced plastic mold.

[0084] In some embodiments, the quartz stone product may be, but is not limited to, a quartz stone sink.

[0085] In some embodiments, see Figure 1 The preparation method of quartz stone products comprises the following steps:

[0086] Step S110: Obtaining non-angular quartz sand of different gradations.

[0087] Step S120: Heat the non-angular quartz sand, inorganic colorant and additives of different gradations, control the heating rate in the heating process from 500°C to 600°C to be 3°C / min~4°C / min, and the heating rate in the heating process from 600°C to the target temperature to be 3°C / min~5°C / min, heat to the target temperature, and keep warm for ≥30 minutes to obtain colored quartz sand, wherein the target temperature is 700°C~1000°C, and the additives include nano alumina.

[0088] Step S130: mixing the colored quartz sand with the hydrolyzate of the silane coupling agent and / or the silica sol, and drying them to obtain modified quartz sand.

[0089] Step S140: Mixing modified quartz sand with resin and curing agent to prepare initial slurry, taking part of the initial slurry and mixing it with additives to prepare reinforced slurry, wherein the additives include one or more of polytetrafluoroethylene wax powder, glass flakes and fumed silica powder.

[0090] Step S150: Turn the mold upside down, add the reinforcing slurry and the remaining initial slurry into the mold respectively, heat and solidify the mold, and demold to prepare a quartz stone product.

[0091] The specific process parameters in each step are as described above and will not be repeated here.

[0092] It should be understood that Figure 1 This is a schematic diagram of a process for preparing a quartz stone product according to an embodiment of the present application. Figure 1 The steps in the flowchart are shown in sequence as indicated by the arrows, but these steps are not necessarily performed in the order indicated by the arrows. Unless otherwise specified in this document, there is no strict order restriction for the execution of these steps, and they can be performed in other orders. Figure 1 At least part of the steps may include multiple sub-steps or multiple stages. These sub-steps or stages are not necessarily executed at the same time, but can be executed at different times. The order of execution is not necessarily sequential, but can be executed in turn or alternately with other steps or at least part of other sub-steps or stages.

[0093] A second aspect of the present application provides a quartz stone product prepared by the above-mentioned method for preparing the quartz stone product.

[0094] In some embodiments, the quartz stone product includes, but is not limited to, a quartz stone sink.

[0095] The quartz stone products have high hardness and wear resistance, as well as good coloring effect, and are not easy to fade during hot and cold shocks.

[0096] In order to make the purpose and advantages of the present application clearer, the quartz stone products, preparation methods and effects of the present application are further described in detail below in conjunction with specific examples. It should be understood that the specific examples described herein are only used to explain the present application and shall not be used to limit the present application. The following examples do not include other components except for unavoidable impurities unless otherwise specified. The drugs and instruments used in the examples are conventionally selected in the art unless otherwise specified. The experimental methods for which specific conditions are not specified in the examples are implemented according to conventional conditions, such as the conditions described in the literature and books or the methods recommended by the manufacturer.

[0097] Example 1

[0098] The embodiment of the present invention provides a quartz stone water tank, and the preparation steps are as follows:

[0099] (1) Material preparation: Use air jet mill to process 20 mesh, 40 mesh, 60 mesh and 80 mesh quartz sand until the edges and corners of the quartz sand disappear. The quartz angle coefficient before treatment is 1.40. After treatment, pass through 40 mesh, 60 mesh, 80 mesh, 100 mesh and 120 mesh sieves. Quartz powder with mesh size greater than 120 mesh is not used. Other quartz sand is used after grading. The graded quartz sand is as follows: 20 mesh ~ 40 mesh 10%, 40 mesh ~ 60 mesh 20%, 60 mesh ~ 80 mesh 30%, 80 mesh ~ 100 mesh 25%, 100 mesh ~ 120 mesh 15%.

[0100] (2) Modification:

[0101] The following raw materials were obtained by mass percentage: 95% graded quartz sand, 3% copper-chromium black material, 1% magnesium oxide and 1% nano-alumina. The above raw materials were mixed and stirred in an alumina crucible, and high-temperature ceramicization was carried out in a muffle furnace. The heating curve was set as follows: 30°C~100°C 5min, 100°C~300°C 15min, 300°C~500°C 25min, 500°C~600°C 30min, 600°C~700°C 30min, and the temperature was increased to 700°C and kept warm for 30min to obtain modified quartz sand.

[0102] The steps of preparing the silane coupling agent hydrolyzate are as follows: prepare 95% ethanol and 5% aqueous solution, add acetic acid to adjust the pH of the solution to 4.5-5.5, and add 2% by mass of the silane coupling agent KH-570 dropwise while stirring, and hydrolyze for 5 minutes to obtain the silane coupling agent hydrolyzate.

[0103] The modified quartz sand and the silane coupling agent hydrolyzate were mixed evenly, and dried in an oven at 100° C. for 2 hours to obtain the modified quartz sand treated with the silane coupling agent, wherein the mass of the silane coupling agent hydrolyzate was 1.2% of the mass of the modified quartz sand.

[0104] (3) Slurry mixing: The following raw materials are obtained by weight percentage: 78.9% of modified quartz sand treated with a silane coupling agent and 21.1% of isophenyl neopentyl glycol resin. Set the mixer speed to 300 rpm, first add the modified quartz sand and mix, then pour the resin in batches and stir for 10 minutes to ensure that the slurry is completely stirred and evenly mixed, then add a curing agent (methyl ethyl ketone peroxide) with a resin weight percentage of 1.2% to obtain an initial slurry. Take out 10% (mass percentage) of the initial slurry, add glass flakes accounting for 1% of the total mass of the modified quartz sand and resin and 2% of polytetrafluoroethylene wax powder to obtain a reinforced slurry. The remaining initial slurry and reinforced slurry are kept in a fast stirring state at a speed of 300 rpm before molding.

[0105] (4) Molding: Preheat the FRP mold to 50°C, turn the mold upside down, first add the reinforcing slurry into the mold cavity, and then slowly add the initial slurry until the slurry overflows from the exhaust hole. Send the mold into the drying room, adjust the temperature to 100°C, and increase the temperature at a rate of 4°C / min. After heating to 100°C, keep the temperature for 2 hours. After the mold cools down, demould it, grind the edges, open holes, and chamfer the demoulded quartz stone sink to obtain the quartz stone sink of this embodiment.

[0106] The quartz sand of this embodiment is processed by air flow mill to obtain the quartz sand without edges and corners. Figure 2 As shown. Figure 2 It can be seen that the treated quartz does not have the edges and corners of ordinary crushed quartz sand. Figure 3 This is a macroscopic enlarged picture of ordinary quartz sand that has not been treated by air jet milling. Figure 3 It can be seen that ordinary quartz sand has more edges and corners. A physical picture of the quartz stone sink prepared in this embodiment is as follows Figure 4 shown.

[0107] Example 2

[0108] This embodiment provides a quartz stone water tank, and the preparation steps are similar to those of the embodiment 1, except that, in step (1), the quartz sand in this embodiment is not treated by air jet milling. The untreated quartz sand is directly graded and used. The graded quartz sand is the same as that in the embodiment 1.

[0109] The other steps are the same as those in Example 1 and will not be described in detail.

[0110] Example 3

[0111] This embodiment provides a quartz stone water tank, and the preparation steps are similar to those of Embodiment 1, except that in step (1), quartz sand with a mesh size of 120 or more is introduced. Specifically, the graded quartz sand is as follows: 20-40 mesh 9.1%, 40-60 mesh 18.2%, 60-80 mesh 27.3%, 80-100 mesh 22.7%, 100-120 mesh 13.6% and 120 mesh or more 9.1%. The other steps and processes are the same as those of Embodiment 1 and will not be repeated here.

[0112] Example 4

[0113] This embodiment provides a quartz stone water tank, and the preparation steps are similar to those of Embodiment 1, except that in step (3), the amount of modified quartz sand treated with a silane coupling agent and isophenyl neopentyl glycol resin is different. In this embodiment, the mass percentage of the modified quartz sand treated with a silane coupling agent is 70%, and the mass percentage of the resin is 30%. The other steps and processes are the same as those of Embodiment 1 and will not be repeated here.

[0114] Example 5

[0115] This embodiment provides a quartz water tank, and the preparation steps are similar to those of embodiment 1, except that the temperature rise curve of the high-temperature heating process in step (2) is different. In this embodiment, the temperature rise curve is set as follows: 30°C~100°C for 5 min, 100°C~300°C for 15 min, 300°C~500°C for 25 min, 500°C~700°C for 30 min, and then the temperature is raised to 700°C and kept warm for 30 min to obtain modified quartz sand.

[0116] The other steps of this embodiment are the same as those of Embodiment 1 and will not be described in detail.

[0117] Example 6

[0118] This embodiment provides a method for preparing a quartz water tank, which is similar to the preparation steps of the quartz water tank in Example 1, except that in step (3), glass flakes are replaced by glass powder. The other steps are the same as those in Example 1 and will not be described in detail.

[0119] Example 7

[0120] This embodiment provides a method for preparing a quartz water tank, which is similar to the method for preparing a quartz water tank in Example 1, except that nano-alumina is not added in step (2), and the mass percentage of magnesium oxide is 2%. The other steps are the same as those in Example 1 and will not be repeated.

[0121] Example 8

[0122] This embodiment provides a quartz stone water tank, and the preparation steps are similar to those of embodiment 1, except that nano-alumina is not added in step (2), but is added during the slurry mixing process of step (3). Specifically, steps (2) and (3) of this embodiment are as follows:

[0123] The following raw materials were obtained by mass percentage: 95% graded quartz sand, 3% copper-chromium black material and 2% magnesium oxide. The above raw materials were mixed and stirred in an alumina crucible, and high-temperature ceramicization was carried out in a muffle furnace. The heating curve was set as follows: 30°C~100°C 5min, 100°C~300°C 15min, 300°C~500°C 25min, 500°C~600°C 30min, 600°C~700°C30min, and the temperature was raised to 700°C and kept warm for 30min to obtain modified quartz sand.

[0124] The steps of preparing the silane coupling agent hydrolyzate are as follows: prepare 95% ethanol and 5% aqueous solution, add acetic acid to adjust the pH of the solution to 4.5-5.5, and add 2% by mass of the silane coupling agent KH-570 dropwise while stirring, and hydrolyze for 5 minutes to obtain the silane coupling agent hydrolyzate.

[0125] The modified quartz sand and the silane coupling agent hydrolyzate were mixed evenly, and dried in an oven at 100° C. for 2 hours to obtain the modified quartz sand treated with the silane coupling agent, wherein the mass of the silane coupling agent hydrolyzate was 1.2% of the mass of the modified quartz sand.

[0126] (3) Slurry mixing: The following raw materials are obtained by weight percentage: 75% of modified quartz sand treated with a silane coupling agent and 20% of isophenyl neopentyl glycol resin. Set the mixer speed to 300 rpm, add the modified quartz sand first, then pour the resin in batches and stir for 10 minutes to ensure that the slurry is completely stirred and evenly mixed, and then add a curing agent (methyl ethyl ketone peroxide) accounting for 1.2% of the total weight percentage of the modified quartz sand and the resin to obtain an initial slurry. Take out 10% (mass percentage) of the initial slurry, add glass flakes accounting for 1% of the total weight of the modified quartz sand and the resin, 2% of polytetrafluoroethylene wax powder and 1% of nano-alumina to it, and obtain a reinforced slurry. The remaining initial slurry and reinforced slurry are kept in a fast stirring state at a speed of 300 rpm before molding.

[0127] Comparative Example 1

[0128] Comparative Example 1 provides a quartz water tank, and the preparation steps are similar to those of Example 1, except that the quartz sand of Comparative Example 1 is not subjected to high temperature treatment. The preparation step (2) of the quartz water tank of Comparative Example 1 is as follows:

[0129] The following raw materials were obtained by mass percentage: 95% graded quartz sand, 3% copper-chromium black material, 1% magnesium oxide and 1% nano-alumina. The raw materials were mixed and stirred in an alumina crucible to obtain a quartz sand mixture.

[0130] The steps of preparing the silane coupling agent hydrolyzate are as follows: prepare 95% ethanol and 5% aqueous solution, add acetic acid to adjust the pH of the solution to 4.5-5.5, and add 2% by mass of the silane coupling agent KH-570 dropwise while stirring, and hydrolyze for 5 minutes to obtain the silane coupling agent hydrolyzate.

[0131] The quartz sand mixture and the silane coupling agent hydrolyzate are mixed evenly, and dried in an oven at 100° C. for 2 hours to obtain modified quartz sand, wherein the mass of the silane coupling agent hydrolyzate is 1.2% of the mass of the quartz sand mixture.

[0132] The other steps of Comparative Example 1 are the same as those of Example 1 and will not be described in detail.

[0133] Comparative Example 2

[0134] Comparative Example 2 provides a method for preparing a quartz water tank, which is similar to the method for preparing a quartz water tank in Example 1, except that in step (2), the high-temperature heating temperature is 600° C. The other steps are similar to those in Example 1 and will not be repeated herein.

[0135] Comparative Example 3

[0136] Comparative Example 3 provides a method for preparing a quartz water tank, which is similar to the method for preparing a quartz water tank in Example 1, except that in step (2), the high-temperature heating temperature is 1100° C. The other steps are similar to those in Example 1 and will not be repeated herein.

[0137] Comparative Example 4

[0138] Comparative Example 4 provides a quartz stone water tank, and the preparation steps are similar to those of Example 1, except that in step (2), the hydrolyzate of the silane coupling agent is not mixed with the modified quartz sand and dried, but the silane coupling agent is added during the slurry mixing process. Specifically, steps (2) and (3) of Comparative Example 4 are as follows:

[0139] (2) The following raw materials were obtained in percentage by mass: 95% graded quartz sand, 3% copper-chromium black material, 1% magnesium oxide and 1% nano-alumina. The above raw materials were mixed and stirred in an alumina crucible, and high-temperature ceramicization was carried out in a muffle furnace. The heating curve was set as follows: 30°C-100°C for 5 min, 100°C-300°C for 15 min, 300°C-500°C for 25 min, 500°C-600°C for 30 min, 600°C-700°C for 30 min, and the temperature was raised to 700°C and kept warm for 30 min to obtain modified quartz sand.

[0140] (3) Slurry mixing: The following raw materials are obtained by weight percentage: 78.9% of modified quartz sand treated with silane coupling agent and 21.1% of isophenyl neopentyl glycol resin. Set the mixer speed to 300 rpm, add the modified quartz sand first, then pour the resin in batches and stir for 10 minutes to ensure that the slurry is completely stirred and evenly mixed. Then add 1.2% of the resin weight percentage of curing agent (methyl ethyl ketone peroxide) and 1.2% of the total weight percentage of the modified quartz sand and resin of silane coupling agent KH-570 to obtain the initial slurry. Take out 10% (mass percentage) of the initial slurry, add 1% of the total weight of the modified quartz sand and resin of glass flakes and 2% of polytetrafluoroethylene wax powder to obtain the reinforced slurry. The remaining initial slurry and reinforced slurry are kept in a fast stirring state at a speed of 300 rpm before molding.

[0141] The other steps of Comparative Example 4 are the same as those of Example 1 and will not be described in detail.

[0142] The quartz stone sinks of the above embodiments and comparative examples were tested as follows, and the test results are shown in Table 1 below.

[0143] 1. Mohs hardness test: JCT 908-2013 Appendix A;

[0144] 2. Hot and cold shock discoloration test: Select a point of the test piece that is more than 5 cm away from the edge. Use 25℃ and 95℃ water from 25 cm away, and shock for 10 seconds each time. Repeat the hot and cold cycle for 120 times, and observe the discoloration of the product.

[0145] Table 1 Test results of various embodiments and comparative examples

[0146]

[0147] As can be seen from Table 1, in Comparative Example 1, the inorganic colorant is mixed with quartz sand during the slurry mixing process, and is not subjected to high-temperature heating treatment. Its coloring effect is poor, and discoloration occurs after 120 times of alternating cold and hot water shocks. In Comparative Example 2, the temperature at which the inorganic colorant and quartz sand are heated is too low, and the coloring effect is poor. After 120 times of alternating cold and hot water shocks, discoloration also occurs. In Comparative Example 3, the temperature at which the inorganic colorant and quartz sand are heated is too high, and the product as a whole changes color. In Comparative Example 4, the silane coupling agent is directly mixed with quartz sand and resin, so that the mixing effect of the resin and quartz sand is not good, some quartz sand is not evenly mixed with the resin, and the product appearance is uneven, resulting in discoloration in the part of the product exposed to quartz sand, while the part exposed to the resin does not fade.

[0148] The technical features of the above-described embodiments may be arbitrarily combined. To make the description concise, not all possible combinations of the technical features in the above-described embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0149] The above-described embodiments only express several implementation methods of the present application, which is convenient for understanding the technical solution of the present application in detail, but it cannot be understood as limiting the scope of protection of the invention patent. It should be pointed out that for ordinary technicians in this field, without departing from the concept of the present application, several modifications and improvements can be made, which all belong to the scope of protection of the present application. It should be understood that the technical solutions obtained by those skilled in the art through logical analysis, reasoning or limited experiments on the basis of the technical solutions provided in the present application are all within the scope of protection of the claims attached to the present application. Therefore, the scope of protection of the patent of this application shall be based on the contents of the attached claims, and the description and drawings can be used to explain the contents of the claims.

Claims

1. A method for preparing a quartz stone product, characterized in that: The steps include: The quartz sand and the inorganic colorant are heated at 700°C to 1000°C to obtain colored quartz sand; The colored quartz sand is mixed with the hydrolyzate of the silane coupling agent and / or silica sol, and dried to obtain modified quartz sand; Mixing the modified quartz sand with resin to obtain slurry; The slurry is shaped to prepare a quartz stone product.

2. The method for preparing a quartz stone product according to claim 1, characterized in that: In the step of heating the quartz sand and the inorganic colorant at 700°C to 1000°C, the heating time is ≥ 30 min; and / or, Before the step of heating quartz sand and inorganic colorant at 700°C~1000°C, during the heating process from 500°C to 600°C, the heating rate is set to 3°C / min~4°C / min, and during the heating process from 600°C to the target temperature, the heating rate is set to 3°C / min~5°C / min, and the target temperature is 700°C~1000°C.

3. The method for preparing a quartz stone product according to claim 1 or 2, characterized in that: In the step of heating the quartz sand and the inorganic colorant at 700° C. to 1000° C., an auxiliary agent is further added, wherein the auxiliary agent comprises nano-alumina, and based on the total mass percentage of the quartz sand, the inorganic colorant and the auxiliary agent as 100%, the mass percentage of the quartz sand is 90% to 95%, the mass percentage of the inorganic colorant is 3% to 5%, and the mass percentage of the auxiliary agent is 1% to 5%; Optionally, the auxiliary agent further includes magnesium oxide.

4. The method for preparing a quartz stone product according to claim 1, characterized in that: The quartz sand is non-angular quartz sand. Optionally, the non-angular quartz sand is obtained by jet milling the quartz sand. and / or, Calculated by weight, the quartz sand includes: 5%-10% of 20-40 mesh quartz sand, 20%-30% of 40-60 mesh quartz sand, 25%-35% of 60-80 mesh quartz sand, 15%-25% of 80-100 mesh quartz sand and 5%-15% of 100-120 mesh quartz sand.

5. The method for preparing a quartz stone product according to claim 1, 2 or 4, characterized in that: The mass of the hydrolyzate of the silane coupling agent and the silica sol is 1% to 2% of the mass of the colored quartz sand respectively; and / or, The preparation step of the hydrolyzate of the silane coupling agent comprises: mixing the silane coupling agent with an ethanol aqueous solution with a pH of 4.5 to 5.5 and hydrolyzing for 5 to 8 minutes, wherein the mass of the silane coupling agent accounts for 2% to 5% of the mass of the ethanol aqueous solution; and / or, In the drying step, the temperature is 80°C to 100°C and the time is 1h to 2h.

6. The method for preparing a quartz stone product according to claim 1, characterized in that: Taking the total mass percentage of the modified quartz sand and the resin as 100%, the mass percentage of the modified quartz sand is 75% to 80%, and the mass percentage of the resin is 20% to 25%; Optionally, a curing agent is further added to the slurry, and the mass of the curing agent accounts for 0.8% to 1.5% of the mass of the resin.

7. The method for preparing a quartz stone product according to claim 6, characterized in that: Additives are also added to the slurry, the mass of the additives accounting for 1% to 5% of the total mass of the modified quartz sand and the resin, and the additives include one or more of polytetrafluoroethylene wax powder, glass flakes and fumed silica powder.

8. The method for preparing a quartz stone product according to claim 7, characterized in that: The slurry includes an initial slurry and a reinforcing slurry, wherein the initial slurry is obtained by mixing the modified quartz sand, the resin and the curing agent, and the reinforcing slurry is obtained by mixing part of the initial slurry with the additive; In the step of molding the slurry, the mold is turned upside down, and the reinforcing slurry and the remaining initial slurry are added to the mold respectively, and heated and cured to form the mold.

9. The method for preparing a quartz stone product according to claim 8, characterized in that: The mass percentage of the part of the initial slurry to the whole of the initial slurry is 8% to 10%; and / or, In the step of heating and curing, the temperature is raised to 80°C~100°C at a heating rate of 1°C / min~4°C / min and kept at this temperature for 1.5h~2h.

10. A quartz stone product, characterized in that: Prepared by the preparation method according to any one of claims 1 to 9; Optionally, the quartz stone product is a quartz stone sink.

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