High-toughness saltpetering-preventing artificial stone plate and preparation method thereof

Abstract

The invention discloses a high-toughness saltpetering-preventing artificial stone plate and a preparation method thereof. The high-toughness saltpetering-preventing artificial stone plate comprises a bottom layer and a surface layer, a stainless steel mesh is embedded in the bottom layer; the bottom layer is prepared from the following raw materials in parts by weight: 120 to 210 parts of quartz sand, 7 to 13 parts of silicon-aluminum mineral material, 50 to 100 parts of cement, 1.8 to 2.5 parts of combined fiber and 8 to 15 parts of water; the surface layer comprises the following raw materials in parts by weight: 120-210 parts of quartz sand, 7-13 parts of a silicon-aluminum mineral material, 2-7 parts of a porous material, 50-100 parts of cement and 8-15 parts of water. The artificial stone plate in the scheme has the advantages of high breaking strength and saltpetering resistance, and can be mounted on the wall body in a dry hanging manner, so that the situation that the artificial stone plate can be mounted on the wall body only by drilling holes is effectively avoided, and the conditions that the artificial stone plate is easy to saltpeter after being used for a long time, and cracks are easy to cause breakage in subsequent use are effectively reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of artificial stone slabs, and in particular to a high-toughness artificial stone slab for preventing efflorescence and its preparation method. Background Art

[0002] The traditional installation method of artificial stone slabs usually includes the following steps: drilling holes in the artificial stone slabs, and then directly fixing the artificial stone slabs on the wall by relying on fixing parts such as screws and bolts. When drilling holes in the artificial stone slabs, the drill bit exerts huge pressure and shear force on the local part of the artificial stone slabs. If the operation is improper or the artificial stone slabs themselves have defects, cracks are very likely to occur around the drilled holes. Installers often can only rely on visual inspection to select artificial stone slabs that seemingly have no cracks on the surface for installation.

[0003] However, many tiny fine lines or internal cracks in the traditional artificial stone slabs are not obvious on the surface of the artificial stone slabs, and are even difficult to detect with the naked eye, and fractures may also occur. For example: during the installation process, uneven support or fixation is received, resulting in excessive local stress, which causes the cracks to become larger; during use, with the change of temperature, the fluctuation of wind force and the action of external forces, they gradually expand, and finally the artificial stone slabs break and fall off.

[0004] In addition, when the traditional artificial stone slabs encounter water penetration, white crystals will form on the surface or gaps of the artificial stone slabs, that is, the so-called "efflorescence". Efflorescence not only seriously damages the original beauty of the artificial stone slabs, making the wall surface appear mottled, but may also further exacerbate the corrosion and aging of the artificial stone slabs, shortening their service life. Summary of the Invention

[0005] The purpose of the present invention is to provide a high-toughness artificial stone slab for preventing efflorescence. In this solution, the artificial stone slab has the advantages of high flexural strength and anti-efflorescence, and solves the problems that the traditional artificial stone slabs are prone to efflorescence when installed on the exterior wall, and are prone to falling and breaking after long-term use.

[0006] Another purpose of the present invention is to provide a preparation method of a high-toughness artificial stone slab for preventing efflorescence, to prepare a high-toughness artificial stone slab that can be installed on the wall by the dry-hanging method, effectively avoiding the need for drilling holes in the artificial stone slab to install it on the wall, simplifying the construction process, and effectively reducing the situation of fractures caused by cracks in the artificial stone slab during subsequent use.

[0007] To achieve this purpose, the present invention adopts the following technical solutions:

[0008] A high-toughness artificial stone slab for preventing efflorescence, comprising a bottom layer and a surface layer; the bottom layer is inlaid with a stainless steel mesh;

[0009] By weight, the raw materials of the bottom layer include 120 - 210 parts of quartz sand, 7 - 13 parts of aluminosilicate mineral material, 50 - 100 parts of cement, 1.8 - 2.5 parts of composite fiber, and 8 - 15 parts of water;

[0010] The raw materials of the surface layer include 120 - 210 parts of quartz sand, 7 - 13 parts of aluminosilicate mineral material, 2 - 7 parts of porous material, 50 - 100 parts of cement, and 8 - 15 parts of water.

[0011] Further, by weight, the composite fiber includes 1.5 - 2.0 parts of stainless steel fiber, 0.1 - 0.3 parts of calcium carbonate whisker, and 0.1 - 0.2 parts of synthetic fiber.

[0012] Further, the synthetic fiber is a combination of one or more of PVA fiber, PE fiber, PP fiber, and POM fiber.

[0013] Further, the stainless steel fiber includes fine stainless steel fiber and coarse stainless steel fiber;

[0014] The length of the coarse stainless steel fiber is 6 - 15 mm, and the diameter is 200 - 600 μm;

[0015] The length of the fine stainless steel fiber is 6 - 15 mm, and the diameter is 45 - 190 μm;

[0016] The aspect ratio of the calcium carbonate whisker is 40 - 60;

[0017] The length of the synthetic fiber is 3 - 19 mm, and the diameter is 45 - 190 μm.

[0018] Further, the aluminosilicate mineral material is a combination of one or more of metakaolin, silica fume, and silica powder.

[0019] Further, the porous material is zeolite powder and diatomaceous earth.

[0020] Further, by weight, the quartz sand includes 50 - 70 parts of 16 - mesh to 26 - mesh quartz sand, 25 - 45 parts of 26 - mesh to 40 - mesh quartz sand, 20 - 40 parts of 40 - mesh to 70 - mesh quartz sand, 20 - 40 parts of 70 - 120 - mesh quartz sand, and 5 - 15 parts of 325 - mesh quartz powder.

[0021] Further, the surface of the artificial stone slab is sprayed with a waterproof agent, and the waterproof agent is a combination of one or more of hydrophobic pore plugs, penetrating crystallization agents, and fluorocarbon - based surface coatings.

[0022] Further, the bottom layer is provided with a stainless - steel profile, the stainless - steel profile is fixedly connected with the stainless - steel mesh, the inner wall of the stainless - steel profile is recessed inward to form a groove, and the artificial stone slab is installed on the wall through the stainless - steel profile.

[0023] A preparation method of a high-toughness artificial stone slab for preventing efflorescence and alkali, comprising the following steps:

[0024] S1. Prepare the bottom layer slurry: Mix the formula amount of silicoaluminous mineral materials, cement and water evenly to obtain a mixed liquid; add the formula amount of quartz sand to the mixed liquid, mix evenly and then add composite fibers, and stir evenly;

[0025] S2. Prepare the surface layer slurry: Stir evenly the formula amount of silicoaluminous mineral materials, porous materials, cement, water and quartz sand.

[0026] S3. Transfer the bottom layer slurry to a template and level it to form a bottom layer. A stainless steel mesh welded with stainless steel profiles is placed in the mold;

[0027] Pour the bottom layer slurry into the mold so that the bottom layer slurry covers the stainless steel mesh; after spreading and pre-pressing, pour the surface layer slurry into the mold, and obtain an artificial stone slab after vibration pressing;

[0028] S4. Spray a waterproof agent on the surface of the artificial stone slab.

[0029] Compared with the prior art, the technical solution proposed by the present invention may have the following beneficial effects:

[0030] 1. The bottom layer of the finished product of the artificial stone slab is also inlaid with a stainless steel mesh. The stainless steel mesh can not only enhance the structural strength of the artificial stone slab, but also withstand greater tensile and shear forces, and can quickly disperse stress, avoiding fracture or damage of the artificial stone slab under the action of drilling, thereby ensuring the service life and safety of the stone slab, enhancing the flexural strength of the artificial stone slab, and reducing the installation cost of the artificial stone slab;

[0031] 2. A variety of fiber materials can fill and refine the pore structure inside the bottom layer, not only improving the compactness of the bottom layer and enhancing the structural strength of the bottom layer; but also reducing the penetration channels of moisture and harmful substances, not only reducing the possibility of moisture and soluble salts penetrating, and contributing to preventing the occurrence of efflorescence and alkali. Specific embodiments

[0032] The technical solution of the present invention will be further described below in conjunction with specific embodiments.

[0033] The present invention provides a high-toughness artificial stone slab for preventing efflorescence and alkali and a preparation method thereof.

[0034] A high-toughness artificial stone slab for preventing efflorescence and alkali, comprising a bottom layer and a surface layer; the bottom layer is inlaid with a stainless steel mesh;

[0035] By weight, the raw materials of the bottom layer include 120-210 parts of quartz sand, 7-13 parts of aluminosilicate mineral material, 50-100 parts of cement, 1.8-2.5 parts of composite fiber, and 8-15 parts of water;

[0036] The raw materials of the surface layer include 120-210 parts of quartz sand, 7-13 parts of aluminosilicate mineral material, 2-7 parts of porous material, 50-100 parts of cement, and 8-15 parts of water.

[0037] Composite fiber and polymer emulsion are added to the bottom layer slurry. The combination of various fiber materials and the polymer emulsion with film-forming effect forms a three-dimensional network structure, enabling the bottom layer to withstand greater external forces and loads, improving the overall stability and crack resistance of the artificial stone slab. Moreover, the combination of various fiber materials and the polymer emulsion not only improves the compactness of the bottom layer, improves the bonding ability between the fiber and the matrix, and enhances the structural strength of the bottom layer; it can also effectively reduce microcracks, thereby reducing the penetration channels of moisture and harmful substances, and helping to prevent the occurrence of efflorescence.

[0038] The migration of alkaline substances such as sodium, potassium, and calcium ions in the pore solution of cement hydration products to the surface of the slab through capillary pores and their accumulation is the root cause of efflorescence. By incorporating a reasonable proportion of aluminosilicate mineral material to react with alkaline substances to form calcium aluminate gel and calcium silicate gel, the number of free calcium ions in the artificial stone slab is reduced, thereby reducing the risk of efflorescence; moreover, calcium aluminate gel and calcium silicate gel can fill the pore structure inside the artificial stone slab, further increasing the compactness of the artificial stone slab, reducing the penetration channels of moisture and harmful substances, and improving the flexural strength performance of the artificial stone slab.

[0039] In addition, a stainless steel mesh is inlaid in the bottom layer of the finished artificial stone slab. The stainless steel mesh can not only enhance the structural strength of the artificial stone slab, but also withstand greater tensile and shear forces, quickly disperse stress, avoid fracture or damage of the artificial stone slab under the action of drilling, thus ensuring the service life and safety of the slab, enhancing the flexural strength of the artificial stone slab, and reducing the installation cost of the artificial stone slab.

[0040] Porous material is added to the surface layer material. The porous material can absorb and lock the moisture and soluble salts inside the artificial stone slab, reducing the chance of their migration to the surface, thereby effectively preventing the occurrence of efflorescence. The synergistic effect of aluminosilicate mineral material and porous material can not only reduce the alkalinity in the surface layer slurry, reduce the formation of a micro-curing environment for soluble salts, promote cement hydration, and form a denser matrix, but also fill the pore structure inside the surface layer, not only improving the compactness and strength of the surface layer, but also reducing the occurrence probability of efflorescence;

[0041] Therefore, the artificial stone slab in this solution has the advantages of high flexural strength and alkali resistance, solving the problems that traditional artificial stone slabs are prone to alkali efflorescence when installed on exterior walls and are likely to fall off and break after long-term use.

[0042] By weight, the composite fiber includes 1.5 - 2.0 parts of stainless steel fiber, 0.1 - 0.3 parts of calcium carbonate whisker, and 0.1 - 0.2 parts of synthetic fiber.

[0043] It should be noted that the composite fibers cross and overlap with each other, forming a grid-like structure in the bottom layer, enabling the bottom layer to withstand greater external forces and loads, and improving the overall stability and durability of the artificial stone slab.

[0044] Stainless steel wire fiber has excellent corrosion resistance and heat resistance, capable of resisting the erosion of environmental factors such as acid-base corrosion and high temperature, thereby extending the service life of the artificial stone slab. Moreover, stainless steel fiber also has the advantages of high strength and high toughness, which can effectively improve the tensile strength and elongation rate of the artificial stone slab, reducing the cracking and breakage phenomena of the artificial stone slab caused by external forces, and effectively solving the problems that traditional artificial stone slabs are likely to fall off and break after long-term use.

[0045] Due to its smaller diameter, the fine stainless steel fiber can better combine with the matrix material to form a denser reinforcement network, further improving the overall toughness of the artificial stone slab, thus effectively enhancing the flexural and crack resistance properties of the artificial stone slab and reducing the possibility of breakage of the artificial stone slab.

[0046] After mixing multiple fiber materials, the internal structure of the artificial stone slab can also be improved, reducing the formation of pores and cracks, thereby reducing the possibility of water and soluble salts permeating, and helping to prevent the occurrence of alkali efflorescence.

[0047] The synthetic fiber is a combination of one or more of PVA fiber, PE fiber, PP fiber, and POM fiber.

[0048] PVA fiber, PE fiber, PP fiber, and POM fiber, these synthetic fibers themselves have good tensile strength. Adding them as reinforcement materials to the artificial stone slab can effectively disperse and bear external forces, thus significantly improving the overall tensile strength of the artificial stone slab. Moreover, synthetic fibers can effectively control the pore structure and water migration path inside the artificial stone slab, reducing the occurrence of alkali efflorescence.

[0049] The stainless steel fiber includes fine stainless steel fiber and coarse stainless steel fiber;

[0050] The length of the coarse stainless steel fiber is 6 - 15 mm, and the diameter is 200 - 600 μm;

[0051] The length of the fine stainless steel fibers is 6 - 15 mm, and the diameter is 45 - 190 μm;

[0052] The aspect ratio of the calcium carbonate whiskers is 40 - 60;

[0053] The length of the synthetic fibers is 3 - 19 mm, and the diameter is 45 - 190 μm.

[0054] The thick stainless steel fibers, with their larger diameter and appropriate length, provide strong tensile strength support for the artificial stone slab, making the artificial stone slab more stable when subjected to external forces and less likely to break or be damaged.

[0055] The synthetic fibers and the fine stainless steel fibers have a smaller diameter, which helps to fill and refine the pore structure inside the artificial stone slab, reducing the penetration channels of moisture and harmful substances. This not only reduces the possibility of moisture and soluble salts penetrating, helps prevent the occurrence of efflorescence, but also improves the density and durability of the artificial stone slab.

[0056] Among them, when the aspect ratio of the calcium carbonate whiskers reaches 40 - 60, its fibrous structure can better combine with the matrix material to form a strong three-dimensional network structure, thus significantly enhancing the overall mechanical strength and toughness of the artificial stone slab. This enhancement effect helps to resist external impacts and deformations and extends the service life of the artificial stone slab.

[0057] Moreover, the calcium carbonate whiskers with a larger aspect ratio, when combined with other fiber materials of different lengths and diameters and mixed together, can form a denser micro-structure in the bottom layer, forming a multi-layer reinforcement system, comprehensively improving the physical properties of the artificial stone slab and further enhancing the overall toughness of the artificial stone slab.

[0058] The aluminosilicate mineral material is one or a combination of metakaolin, silica fume, and silica powder.

[0059] The components of metakaolin, silica fume, and silica powder are all silicon dioxide and aluminum oxide. Among them, the active silicon dioxide exists in the form of a silicon-oxygen network structure, and the active aluminum oxide exists in the form of an aluminum-oxygen network structure. When the cement material undergoes a hydration reaction, it will produce alkaline substances such as calcium hydroxide. Under the action of the alkaline substances, the silicon-oxygen chains in the silicon-oxygen network structure and the aluminum-oxygen chains in the aluminum-oxygen network structure both depolymerize, generating a large number of depolymerized monomer ions, so that the active silicon dioxide and active aluminum oxide in the aluminosilicate mineral material are fully released; at the same time, the above monomer ions undergo a polycondensation reaction again in the alkaline environment to form aluminates and silicates, and the aluminates and silicates can react with the alkaline substances after the hydration of the cement to form calcium aluminate gel and calcium silicate gel.

[0060] The formation of calcium aluminate gel and calcium silicate gel can not only reduce the number of free calcium ions in the artificial stone slab, thereby reducing the occurrence of efflorescence; but also increase the compactness of the artificial stone slab, reduce the porosity of the artificial stone slab, reduce the precipitation of calcium ions in the artificial stone slab, further improve the anti-efflorescence effect of the artificial stone slab in this solution, and improve the flexural strength performance of the artificial stone slab.

[0061] The porous material is zeolite powder and diatomaceous earth.

[0062] Zeolite powder and diatomaceous earth are rich in active silica and alumina. Therefore, the active admixture contacts with the alkaline substances in the cement and undergoes a decomposition reaction to form gel substances such as calcium silicate hydrate and calcium aluminate hydrate, thereby reducing the precipitation of alkaline substances, reducing the alkalinity of the artificial stone slab, and further improving the anti-efflorescence effect of the artificial stone slab.

[0063] Moreover, both zeolite powder and diatomaceous earth have a relatively complex pore structure, can adsorb more alkaline substances, and fix the alkaline substances precipitated on the surface of the surface layer, reducing the accumulation of alkaline substances on the surface area of the surface layer, and further reducing the occurrence of efflorescence.

[0064] In addition, both zeolite powder and diatomaceous earth have a certain rigidity and hardness, and when added to artificial stone, they can act as a reinforcing skeleton. They can form a three-dimensional support structure in the artificial stone matrix, help disperse external forces, reduce the stress concentration phenomenon, and thus improve the flexural strength and compressive strength of artificial stone to a certain extent.

[0065] During the curing process of artificial stone, the porous material may undergo some ion exchange reactions with other components, which helps to form more stable chemical bonds and cross-linked structures, thereby enhancing the internal bonding force of artificial stone and improving the flexural and compressive strengths. Among them, silicon elements in zeolite powder and diatomaceous earth may also undergo chemical reactions with the components in the matrix to generate some substances with cementing effects, further improving the flexural strength and compressive strength of the artificial stone finished product.

[0066] There may be some micro-pores in the preparation process of artificial stone, and these pores will weaken the strength of artificial stone. The particles of zeolite powder and diatomaceous earth can fill these pores, make the internal structure of artificial stone more compact, reduce defects, and improve the overall mechanical properties.

[0067] By weight, the quartz sand includes 50 - 70 parts of 16 - 26 mesh quartz sand, 25 - 45 parts of 26 - 40 mesh quartz sand, 20 - 40 parts of 40 - 70 mesh quartz sand, 20 - 40 parts of 70 - 120 mesh quartz sand, and 5 - 15 parts of 325 mesh quartz powder.

[0068] By mixing quartz sands of different mesh sizes, a multi-level gradation of quartz sands is achieved. Coarse-grained quartz sands can provide higher strength and structural support for the artificial stone slab, while fine-grained quartz sands can fill the voids between the coarse-grained quartz sands, enhancing the overall density and toughness of the artificial stone slab, enabling the artificial stone slab to more effectively disperse stress when subjected to external forces, thereby improving its impact resistance, bending resistance and other properties.

[0069] Among them, the addition of 325-mesh quartz powder effectively fills the tiny pores and cracks inside the artificial stone slab, further preventing the occurrence of efflorescence and maintaining the beauty and durability of the artificial stone slab.

[0070] The surface of the artificial stone slab is sprayed with a waterproof agent, and the waterproof agent is one or a combination of hydrophobic pore plugs, penetrating crystalline agents, and fluorocarbon-based surface coatings.

[0071] Hydrophobic pore plugs, penetrating crystalline agents, and fluorocarbon-based surface coatings can all endow the surface of the artificial stone slab with excellent hydrophobic properties, making it difficult for water to stay and penetrate on the surface of the artificial stone slab, thereby improving the waterproof performance of the artificial stone slab, reducing the outward precipitation and penetration of soluble salt substances under the action of rainwater, and further preventing the occurrence of efflorescence.

[0072] The bottom layer is provided with stainless steel profiles, the stainless steel profiles are fixedly connected with the stainless steel mesh, the inner wall of the stainless steel profiles is recessed inward to form grooves, and the artificial stone slab is installed on the wall through the stainless steel profiles.

[0073] When an external force acts on the artificial stone slab, the stainless steel mesh can respond quickly, dispersing the concentrated stress to a wider area, thus avoiding damage caused by excessive local stress. The stainless steel profiles transfer the dispersed stress from the artificial stone slab to the wall direction and further disperse and absorb these stresses in the process.

[0074] Therefore, the stainless steel profiles are fixedly connected with the stainless steel mesh sheets, enhancing the structural strength of the artificial stone slab, improving the flexural strength of the artificial stone slab, and effectively dispersing the stress that might originally be concentrated in a certain area of the artificial stone slab to the entire wall system, thus avoiding the risk of local damage or even overall detachment of the artificial stone slab.

[0075] Moreover, the artificial stone slab of this solution can be installed on the wall by the dry-hanging method, simplifying the construction process and reducing the time and labor costs of wet operations.

[0076] A preparation method of a high-toughness and efflorescence-preventing artificial stone slab, used to prepare a high-toughness and efflorescence-preventing artificial stone slab as described in claim 9, includes the following steps:

[0077] S1. Prepare the bottom layer slurry: Mix the formula amounts of silicoaluminous mineral materials, cement, and water evenly to obtain a mixed liquid; add the formula amount of quartz sand to the mixed liquid, mix evenly, then add the composite fiber, and stir evenly.

[0078] S2. Prepare the surface layer slurry: Stir evenly the formula amounts of silicoaluminous mineral materials, porous materials, cement, water, and quartz sand.

[0079] S3. Transfer the bottom layer slurry to a mold and spread it flat to form the bottom layer. Place a stainless steel mesh welded with stainless steel profiles in the mold.

[0080] Pour the bottom layer slurry into the mold so that the bottom layer slurry covers the stainless steel mesh; after spreading and pre-pressing, pour the surface layer slurry into the mold, and obtain an artificial stone slab after vibration pressing.

[0081] S4. Spray a waterproof agent on the surface of the artificial stone slab.

[0082] Through this preparation method, an artificial stone slab with alkali resistance, high flexural strength, and high toughness can be prepared. It should be noted that when preparing the bottom layer slurry, after the basic raw materials such as silicoaluminous mineral materials, cement, water, and quartz sand are fully mixed evenly, the composite fiber is slowly added while continuing to stir to ensure that the fiber material can be evenly dispersed in the bottom layer slurry, thereby enhancing the structural strength of the bottom layer.

[0083] Moreover, in this solution, stainless steel meshes and stainless steel profiles are inlaid, so that the artificial stone slab of this solution can be installed on the wall by the dry-hanging method, effectively avoiding the need to drill holes in the artificial stone slab for installation on the wall, simplifying the construction process, and effectively reducing the situation that cracks in the artificial stone slab lead to fractures in subsequent use.

[0084] The present invention will be further elaborated below in conjunction with examples and comparative examples.

[0085] Examples 1 - 4

[0086] Refer to the preparation of each raw material listed in Table 1 below, and prepare a high-toughness alkali-proof artificial stone slab of Examples 1 - 4 according to the following steps.

[0087] A preparation method of a high-toughness alkali-proof artificial stone slab includes the following steps:

[0088] S1. Prepare the bottom layer slurry: By weight, stir evenly 7 - 13 parts of silicoaluminous mineral materials, 50 - 100 parts of cement, 8 - 15 parts of water, 120 - 210 parts of quartz sand, and 1.8 - 2.5 parts of composite fiber;

[0089] S2. Prepare the surface layer slurry: Stir evenly 7 - 13 parts of silicoaluminous mineral materials, 2 - 7 parts of porous materials, 50 - 100 parts of cement, 8 - 15 parts of water, and 120 - 210 parts of quartz sand.

[0090] S3. Transfer the bottom layer slurry to the template and level it to form the bottom layer. Place a stainless steel mesh welded with stainless steel profiles in the mold.

[0091] Pour the bottom layer slurry into the mold until the stainless steel mesh is covered. After leveling and pre-pressing, pour the surface layer slurry into the mold and obtain artificial stone slabs after vibration pressing.

[0092] S4. Spray a waterproof agent on the surface of the artificial stone slab. The waterproof agent is one or a combination of hydrophobic pore plugs, penetrating crystalline agents, and fluorocarbon surface coatings.

[0093] Among them, the composite fiber includes 2 parts of stainless steel fiber, 0.1 part of calcium carbonate whisker, and 0.2 part of synthetic fiber. The synthetic fiber is a combination of one or more of PVA fiber, PE fiber, PP fiber, and POM fiber. The aluminosilicate mineral material is a combination of one or more of metakaolin, silica fume, and silica powder. The porous material is zeolite powder and diatomaceous earth.

[0094] The stainless steel fiber includes fine stainless steel fiber and coarse stainless steel fiber; the length of the coarse stainless steel fiber is 6 - 15 mm, and the diameter is 200 - 600 μm; the length of the fine stainless steel fiber is 6 - 15 mm, and the diameter is 45 - 190 μm; the aspect ratio of the calcium carbonate whisker is 40 - 60; the length of the synthetic fiber is 3 - 19 mm, and the diameter is 45 - 190 μm.

[0095] The quartz sand includes 60 parts of 16 - 26 mesh quartz sand, 35 parts of 26 - 40 mesh quartz sand, 33 parts of 40 - 70 mesh quartz sand, 30 parts of 70 - 120 mesh quartz sand, and 10 parts of 325 mesh quartz powder.

[0096] Table 1

[0097]

[0098]

[0099] Comparative Example 1

[0100] Proportion 1 is basically the same as Example 4, except that: S3. Transfer the bottom layer slurry to the template and level it to form the bottom layer. No stainless steel profiles are placed in the mold. Pour the bottom layer slurry into the mold. After leveling and pre-pressing, pour the surface layer slurry into the mold and obtain artificial stone slabs after vibration pressing.

[0101] Comparative Example 2

[0102] Proportion 2 is basically the same as Example 4, except that: S4. Do not spray a waterproof agent on the surface of the artificial stone slab.

[0103] Comparative Example 3

[0104] Comparative Example 3 is basically the same as Example 4, except that: the combined fiber is 1.3 parts of coarse stainless steel fiber.

[0105] Comparative Example 4

[0106] Comparative Example 4 is basically the same as Example 4, except that: no porous material is added to the surface layer slurry.

[0107] After curing the artificial stone slabs prepared in the above examples and comparative examples in a standard curing room at a temperature of 20±2°C and a humidity greater than 95% for 28 days, observe and record the surface efflorescence phenomenon of the artificial stone slab products, and use the test method of "GB / T 28635-2012 Concrete Pavement Bricks" to test the flexural strength and compressive strength performance of the artificial stone slabs prepared in the above examples and comparative examples after 28 days. The specific test results are shown in Table 2.

[0108] Table 2 Test Results of Related Properties of Artificial Stone Slabs

[0109]

[0110]

[0111] It can be seen from the test results in Table 2 that the artificial stone slabs prepared in Examples 1-4 of the present application have high flexural strength and compressive strength, and have the effect of resisting efflorescence, indicating that the artificial stone slabs produced by using the formula and preparation method of the present application can improve the defect of easy efflorescence while increasing the strength, and can solve the risk of easy efflorescence of traditional artificial stone slabs after long-term use.

[0112] The difference between Comparative Example 1 and Example 4 is that: Comparative Example 1 lacks a stainless steel mesh to disperse stress. When the artificial stone product prepared in Comparative Example 1 is subjected to an external force, the stress is concentrated at a certain place, resulting in cracking or damage of the artificial stone slab. Therefore, the flexural strength and compressive strength of the artificial stone product prepared in Comparative Example 1 are poorer than those of the artificial stone product prepared in Example 4.

[0113] The difference between Comparative Example 2 and Example 4 is that: Comparative Example 2 lacks a waterproof agent, resulting in poor waterproof performance on the surface of the artificial stone. At this time, soluble salt substances precipitate and penetrate outward under the action of rainwater, resulting in the efflorescence phenomenon. Therefore, the preparation method of Comparative Example 2 cannot solve the problem of easy efflorescence of traditional artificial stone.

[0114] The difference between Comparative Example 3 and Example 4 is that only crude stainless steel fibers are used in Comparative Example 3, and the density of crude stainless steel fibers is relatively large, generally much higher than that of polymer emulsions. During the mixing process, due to the effect of gravity, stainless steel fibers tend to sink, while polymer emulsions are relatively light and tend to float, resulting in stratification of the two in the slurry, making it difficult to maintain uniform mixing. At this time, it is difficult for the crude stainless steel fibers and polymer emulsions to mix to form a uniform and stable slurry, and thus it is impossible to form a three-dimensional network structure. When the bottom layer is subjected to external force, local stress concentration is likely to occur, affecting the overall structural stability of the artificial stone slab. Therefore, the flexural strength and compressive strength of the artificial stone finished product prepared in Comparative Example 3 are inferior to those of the artificial stone finished product prepared in Example 4.

[0115] In addition, the combination of multiple fiber materials and polymer emulsions not only improves the compactness of the bottom slurry, but also effectively reduces microcracks, thereby reducing the penetration channels of water and harmful substances, and helps prevent the occurrence of efflorescence. In Comparative Example 3, only coarse stainless steel fibers and polymer emulsions are mixed, which is difficult to improve the compactness of the bottom slurry, resulting in microcracks in the prepared artificial stone product, forming penetration channels for water and harmful substances, and then efflorescence. Therefore, the preparation method of Comparative Example 3 cannot solve the problem of easy efflorescence of traditional artificial stone.

[0116] The difference between Comparative Example 4 and Example 4 is that the lack of porous material adsorption of alkaline substances in Comparative Example 4 causes alkaline substances to accumulate on the surface of the surface layer, resulting in alkali efflux. In addition, the siliceous aluminum mineral material and the porous material work together to fill the pore structure inside the surface layer, which not only improves the density and strength of the surface layer. The lack of synergy between the siliceous aluminum mineral material and the porous material in Comparative Example 4 results in the artificial stone product prepared in Comparative Example 4 having poor internal bonding strength compared with the artificial stone product prepared in Example 4. Therefore, the flexural strength and compressive strength of the artificial stone product prepared in Comparative Example 4 are inferior to those of the artificial stone product prepared in Example 4, and the preparation method of Comparative Example 4 cannot solve the problem of easy alkali efflux of traditional artificial stone.

[0117] The technical principle of the present invention is described above in conjunction with specific embodiments. These descriptions are only for explaining the principle of the present invention and cannot be interpreted as limiting the scope of protection of the present invention in any way. Based on the explanations herein, those skilled in the art can associate other specific implementations of the present invention without paying creative labor, and these methods will fall within the scope of protection of the present invention.

Claims

1. A high-toughness artificial stone slab that prevents efflorescence, characterized in that: It comprises a bottom layer and a surface layer; the bottom layer is inlaid with a stainless steel mesh; By weight, the raw materials of the bottom layer include 120-210 parts of quartz sand, 7-13 parts of silica-alumina mineral materials, 50-100 parts of cement, 1.8-2.5 parts of composite fibers and 8-15 parts of water; The raw materials of the surface layer include 120-210 parts of quartz sand, 7-13 parts of silica-alumina mineral materials, 2-7 parts of porous materials, 50-100 parts of cement and 8-15 parts of water.

2. The high-toughness anti-efflorescence artificial stone slab according to claim 1, characterized in that: In parts by weight, the composite fiber comprises 1.5-2.0 parts of stainless steel fiber, 0.1-0.3 parts of calcium carbonate whisker and 0.1-0.2 parts of synthetic fiber.

3. The high-toughness anti-efflorescence artificial stone slab according to claim 1, characterized in that: The synthetic fiber is a combination of one or more of PVA fiber, PE fiber, PP fiber and POM fiber.

4. The high-toughness anti-efflorescence artificial stone slab according to claim 2, characterized in that: The stainless steel fibers include fine stainless steel fibers and coarse stainless steel fibers; The length of the crude stainless steel fiber is 6-15 mm and the diameter is 200-600 μm; The length of the fine stainless steel fiber is 6-15 mm and the diameter is 45-190 μm; The aspect ratio of the calcium carbonate whisker is 40-60; The length of the synthetic fiber is 3-19 mm and the diameter is 45-190 μm.

5. The high-toughness anti-efflorescence artificial stone slab according to claim 1, characterized in that: The alumina-silica mineral material is a combination of one or more of metakaolin, silica fume and silica powder.

6. The high-toughness anti-efflorescence artificial stone board according to claim 4, characterized in that: The porous materials are zeolite powder and diatomaceous earth.

7. The high-toughness anti-efflorescence artificial stone slab according to claim 1, characterized in that: In parts by weight, the quartz sand includes 50-70 parts of 16-26 mesh quartz sand, 25-45 parts of 26-40 mesh quartz sand, 20-40 parts of 40-70 mesh quartz sand, 20-40 parts of 70-120 mesh quartz sand and 5-15 parts of 325 mesh quartz powder.

8. The high-toughness anti-efflorescence artificial stone slab according to claim 1, characterized in that: The surface of the artificial stone board is sprayed with a waterproof agent, which is one or a combination of hydrophobic pore plugs, penetrating crystallization agents, and fluorocarbon covering agents.

9. The high-toughness anti-efflorescence artificial stone board according to claim 8, characterized in that: The bottom layer is provided with a stainless steel profile, the stainless steel profile is fixedly connected to the stainless steel mesh, the inner wall of the stainless steel profile is recessed inward to form a groove, and the artificial stone slab is installed on the wall through the stainless steel profile.

10. A method for preparing a high-toughness artificial stone slab that prevents efflorescence, characterized in that: The method for preparing a high-toughness anti-efflorescence artificial stone board as claimed in claim 9 comprises the following steps: S1. Prepare the bottom slurry: mix the formulated amount of silicon-aluminum mineral material, cement and water to obtain a mixed solution; add the formulated amount of quartz sand to the mixed solution, mix well, then add the composite fiber and stir well; S2. Prepare the surface slurry: mix the formulated amount of silicon-aluminum mineral material, porous material, cement, water and quartz sand evenly; S3, transferring the bottom slurry to the template and flattening it to form a bottom layer, and placing a stainless steel mesh welded with a stainless steel profile in the mold; Pour the bottom slurry into the mold, and the bottom slurry covers the stainless steel mesh; after flattening and pre-pressing, pour the surface slurry into the mold, and vibrate and press to obtain the artificial stone slab; S4. Waterproofing agent is sprayed on the surface of the artificial stone slab.

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