High-toughness artificial stone panel for preventing efflorescence and method for manufacturing the same

Abstract

This invention discloses a high-toughness, efflorescence-resistant artificial stone slab and its preparation method. The high-toughness, efflorescence-resistant artificial stone slab includes a base layer and a surface layer. The base layer is inlaid with stainless steel mesh. By weight, the raw materials of the base layer include 120-210 parts of quartz sand, 7-13 parts of silica-alumina mineral material, 50-100 parts of cement, 1.8-2.5 parts of composite fiber, 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 material, 2-7 parts of porous material, 50-100 parts of cement, and 8-15 parts of water. The artificial stone slab of this solution has the advantages of high flexural strength and efflorescence resistance. It can be installed on the wall by dry hanging, effectively avoiding the need for drilling holes for wall installation. This effectively reduces the likelihood of efflorescence and cracking after long-term use, which can lead to breakage in subsequent use.

Description

Technical Field

[0001] This invention relates to the field of artificial stone slab technology, and in particular to a high-toughness artificial stone slab that prevents efflorescence and its preparation method. Background Technology

[0002] Traditional artificial stone slab installation methods typically involve drilling holes in the slab and then using screws, bolts, or other fasteners to directly fix the slab to the wall. During drilling, the drill bit applies significant pressure and shear force to the slab locally. Improper operation or defects in the slab itself can easily cause cracks around the drilled holes. Installers often have to rely on visual inspection to select slabs that appear crack-free for installation.

[0003] However, many tiny cracks or internal fissures in traditional artificial stone slabs are not obvious on the surface and are even difficult to detect with the naked eye, which can still lead to breakage. For example, uneven support or fixation during installation can cause excessive local stress, resulting in the cracks widening; during use, changes in temperature, wind fluctuations, and external forces can cause the cracks to gradually expand, eventually leading to the artificial stone slab breaking and falling off.

[0004] Furthermore, when traditional artificial stone slabs are exposed to moisture, white crystals, known as "efflorescence," will form on the surface or in the crevices. Efflorescence not only severely damages the original aesthetics of the artificial stone slabs, making the walls appear mottled and unsightly, but it can also further accelerate the corrosion and aging of the artificial stone slabs, shortening their lifespan. Summary of the Invention

[0005] The purpose of this invention is to propose a high-toughness artificial stone slab that prevents efflorescence. The artificial stone slab in this solution has the advantages of high flexural strength and efflorescence resistance, which solves the problems of traditional artificial stone slabs being prone to efflorescence when installed on exterior walls, and being prone to falling off and breaking after long-term use.

[0006] Another objective of this invention is to propose a method for preparing a high-toughness, efflorescence-resistant artificial stone slab, which produces a high-toughness artificial stone slab that can be dry-hung onto a wall. This effectively avoids the need for drilling holes in the artificial stone slab before installation, simplifies the construction process, and effectively reduces the likelihood of cracks in the artificial stone slab causing breakage during subsequent use.

[0007] To achieve this objective, the present invention adopts the following technical solution:

[0008] A highly resilient, efflorescence-resistant artificial stone slab includes a base layer and a surface layer; the base 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 silica-alumina mineral materials, 50-100 parts of cement, 1.8-2.5 parts of composite fiber and 8-15 parts of water.

[0010] The raw materials for 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.

[0011] Furthermore, by weight, the composite fiber comprises 1.5-2.0 parts stainless steel fiber, 0.1-0.3 parts calcium carbonate whiskers, and 0.1-0.2 parts synthetic fiber.

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

[0013] Furthermore, the stainless steel fibers include fine stainless steel fibers and coarse stainless steel fibers;

[0014] The coarse stainless steel fibers have a length of 6-15 mm and a diameter of 200-600 μm;

[0015] The fine stainless steel fibers have a length of 6-15 mm and a diameter of 45-190 μm;

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

[0017] The synthetic fiber has a length of 3-19 mm and a diameter of 45-190 μm.

[0018] Furthermore, the silica-alumina mineral material is one or more of metakaolin, silica fume, and silica powder.

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

[0020] Furthermore, by weight, the quartz sand comprises 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.

[0021] Furthermore, the surface of the artificial stone slab is sprayed with a waterproofing agent, which is one or a combination of several of the following: hydrophobic plugs, penetrating crystallizers, and fluorocarbon coating agents.

[0022] Furthermore, the bottom layer is provided with a stainless steel profile, which 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.

[0023] A method for preparing a highly resilient, efflorescence-resistant artificial stone slab includes the following steps:

[0024] S1. Preparation of the base slurry: Mix the formulated amount of aluminosilicate mineral materials, cement and water evenly to obtain a mixture; add the formulated amount of quartz sand to the mixture, mix evenly, then add the composite fiber and stir evenly.

[0025] S2. Preparation of surface slurry: Mix the formulated amounts of aluminosilicate mineral materials, porous materials, cement, water and quartz sand evenly.

[0026] S3. Transfer the bottom slurry to the template and spread it flat to form the bottom layer. Place a stainless steel mesh with welded stainless steel profiles inside the mold.

[0027] Pour the bottom layer of slurry into the mold, ensuring it covers the stainless steel mesh; after flattening and pre-pressing, pour the top layer of slurry into the mold, and then vibrate and press to obtain the artificial stone slab.

[0028] S4. A waterproofing agent is sprayed onto the surface of the artificial stone slab.

[0029] Compared with the prior art, the technical solution proposed in this invention can have the following beneficial effects:

[0030] 1. The bottom layer of the finished artificial stone slab is inlaid with 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. It can quickly disperse stress and prevent the artificial stone slab from breaking or being damaged during the drilling process, 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. Various fiber materials can fill and refine the pore structure inside the bottom layer, which not only improves the density of the bottom layer and enhances its structural strength, but also reduces the penetration channels of water and harmful substances, thus reducing the possibility of water and soluble salt penetration and helping to prevent efflorescence. Detailed Implementation

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

[0033] This invention provides a highly tough artificial stone slab that prevents efflorescence and a method for preparing the same.

[0034] A highly resilient, efflorescence-resistant artificial stone slab includes a base layer and a surface layer; the base 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 silica-alumina mineral materials, 50-100 parts of cement, 1.8-2.5 parts of composite fiber and 8-15 parts of water.

[0036] The raw materials for 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.

[0037] The bottom slurry incorporates a combination of fibers and polymer emulsions. This combination of multiple fiber materials and film-forming polymer emulsions creates a three-dimensional network structure, enabling the bottom layer to withstand greater external forces and loads, thus improving the overall stability and crack resistance of the artificial stone slab. Furthermore, the combination of various fiber materials and polymer emulsions not only enhances the density of the bottom layer and improves the bonding between the fibers and the matrix, strengthening its structural strength, but also effectively reduces microcracks, thereby decreasing the channels for the penetration of moisture and harmful substances and helping to prevent efflorescence.

[0038] The fundamental cause of efflorescence is the migration and accumulation of alkaline substances such as sodium, potassium, and calcium ions from the pore solution of cement hydration products onto the surface of the slab through capillary pores. By incorporating a reasonable proportion of aluminosilicate mineral materials to react with alkaline substances and generate 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 its density, reducing the penetration channels of moisture and harmful substances, and improving the flexural strength of the artificial stone slab.

[0039] In addition, the bottom layer of the finished artificial stone slab is inlaid with 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. It can quickly disperse stress and prevent the artificial stone slab from breaking or being damaged during the drilling process, thereby ensuring the service life and safety of the stone slab, enhancing its flexural strength and reducing its installation cost.

[0040] Adding porous materials to the surface layer allows them to absorb and lock in moisture and soluble salts within the artificial stone slab, reducing their migration to the surface and effectively preventing efflorescence. The synergistic effect of the aluminosilicate mineral materials and the porous materials not only reduces the alkalinity of the surface layer slurry, minimizing the formation of a micro-curing environment for soluble salts and promoting cement hydration to create a denser matrix, but also fills the pores within the surface layer, improving its density and strength and further reducing the likelihood of efflorescence.

[0041] Therefore, the artificial stone slabs in this solution have the advantages of high flexural strength and efflorescence resistance, solving the problems of traditional artificial stone slabs being prone to efflorescence when installed on exterior walls, and being prone to falling off and breaking after long-term use.

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

[0043] It is worth noting that the composite fibers interweave and overlap to form a mesh structure in the bottom layer, which enables the bottom layer to withstand greater external forces and loads, thereby improving the overall stability and durability of the artificial stone slab.

[0044] Stainless steel fiber has excellent corrosion resistance and heat resistance, enabling it to resist environmental factors such as acid and alkali corrosion and high temperatures, thereby extending the service life of artificial stone slabs. Furthermore, stainless steel fiber also possesses high strength and high toughness, effectively improving the tensile strength and elongation of artificial stone slabs, reducing cracking and damage caused by external forces, and effectively solving the problem of traditional artificial stone slabs easily falling off and breaking after long-term use.

[0045] Due to their smaller diameter, fine stainless steel fibers can better integrate with the matrix material to form a denser reinforcing network, further improving the overall toughness of artificial stone slabs. This effectively enhances the flexural and crack resistance of artificial stone slabs, reducing the possibility of breakage.

[0046] The mixing of various fiber materials can also improve the internal structure of artificial stone slabs, reduce the formation of pores and cracks, thereby reducing the possibility of water and soluble salt penetration and helping to prevent efflorescence.

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

[0048] PVA, PE, PP, and POM fibers are synthetic fibers that inherently possess good tensile strength. Adding them as reinforcement materials to artificial stone slabs can effectively disperse and bear external forces, thus significantly improving the overall tensile strength of the slabs. Furthermore, synthetic fibers can effectively control the internal pore structure and moisture migration pathways of the artificial stone slabs, reducing the occurrence of efflorescence.

[0049] The stainless steel fibers include fine stainless steel fibers and coarse stainless steel fibers;

[0050] The coarse stainless steel fibers have a length of 6-15 mm and a diameter of 200-600 μm;

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

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

[0053] The synthetic fiber has a length of 3-19 mm and a diameter of 45-190 μm.

[0054] With its large diameter and appropriate length, the coarse stainless steel fiber provides strong tensile strength support for the artificial stone slab, making it more stable when subjected to external forces and less prone to breakage or damage.

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

[0056] When the aspect ratio of calcium carbonate whiskers reaches 40-60, their fibrous structure can better bond with the matrix material, forming a strong three-dimensional network structure, thereby significantly improving the overall mechanical strength and toughness of the artificial stone slab. This reinforcing effect helps resist external impacts and deformation, extending the service life of the artificial stone slab.

[0057] Moreover, calcium carbonate whiskers with a large aspect ratio, when combined with other fiber materials of different lengths and diameters, can form a denser microstructure in the bottom layer after being mixed together, forming a multi-layered reinforcement system, which comprehensively improves the physical properties of artificial stone slabs and further enhances their overall toughness.

[0058] The silicoaluminous mineral material is one or more of metakaolin, silica fume, and silica powder.

[0059] Metakaolin, silica fume, and silica fume are all composed of silicon dioxide and aluminum oxide. Active silicon dioxide exists in a silicon-oxygen network structure, while active aluminum oxide exists in an aluminum-oxygen network structure. During the hydration reaction of cement materials, alkaline substances such as calcium hydroxide are produced. Under the influence of these alkaline substances, the silicon-oxygen chains in the silicon-oxygen network structure and the aluminum-oxygen chains in the aluminum-oxygen network structure depolymerize, generating a large number of depolymerized monomer ions. This allows the active silicon dioxide and active aluminum oxide in the siliceous alumina mineral materials to be fully released. Simultaneously, these monomer ions undergo a condensation reaction in the alkaline environment to generate aluminates and silicates. Furthermore, aluminates and silicates can undergo secondary reactions with the alkaline substances produced after cement hydration 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 artificial stone slabs, thereby reducing the occurrence of efflorescence, but also increase the density of artificial stone slabs, reduce the porosity of artificial stone slabs, reduce the precipitation of calcium ions in artificial stone slabs, further improve the efflorescence prevention effect of artificial stone slabs in this solution, and improve the flexural strength of artificial stone slabs.

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

[0062] Zeolite powder and diatomaceous earth are rich in active silica and alumina. Therefore, when the active admixture comes into contact with the alkaline substances in cement, a decomposition reaction occurs, forming gel substances such as hydrated calcium silicate and hydrated calcium aluminate. This reduces the precipitation of alkaline substances, lowers the alkalinity of the artificial stone slab, and thus improves the anti-efflorescence effect of the artificial stone slab.

[0063] Moreover, both zeolite powder and diatomaceous earth have relatively complex pore structures, which 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 layer and further reducing the occurrence of efflorescence.

[0064] In addition, zeolite powder and diatomaceous earth both possess a certain degree of rigidity and hardness, which can be added to artificial stone as a reinforcing skeleton. They can form a three-dimensional support structure in the artificial stone matrix, helping to disperse external forces and reduce stress concentration, thereby improving the flexural and compressive strength of artificial stone to a certain extent.

[0065] During the curing process of artificial stone, porous materials may undergo ion exchange reactions with other components, helping to form more stable chemical bonds and cross-linked structures, thereby enhancing the internal bonding force of the artificial stone and improving its flexural and compressive strength. In particular, silicon elements in zeolite powder and diatomaceous earth may also react chemically with components in the matrix to generate substances with cementing properties, further improving the flexural and compressive strength of the finished artificial stone product.

[0066] Artificial stone may contain some tiny pores during its manufacturing process, which can weaken its strength. Zeolite powder and diatomaceous earth particles can fill these pores, making the internal structure of the artificial stone denser, reducing defects, and improving its overall mechanical properties.

[0067] By weight, the quartz sand comprises 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 sand of different mesh sizes, a multi-level gradation of quartz sand is achieved. Coarse-grained quartz sand provides higher strength and structural support for the artificial stone slab, while fine-grained quartz sand fills the gaps between the coarse-grained quartz sand, enhancing the overall density and toughness of the artificial stone slab. This allows 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] The addition of 325-mesh quartz powder effectively fills the tiny pores and cracks inside the artificial stone slab, further preventing efflorescence and maintaining the beauty and durability of the artificial stone slab.

[0070] The surface of the artificial stone slab is sprayed with a waterproofing agent, which is one or a combination of several of the following: hydrophobic plugs, penetrating crystallizers, and fluorocarbon coating agents.

[0071] Hydrophobic plugs, penetrating crystallizers, and fluorocarbon coating agents can all impart excellent hydrophobic properties to the surface of artificial stone slabs, making it difficult for water to remain and penetrate the surface, thereby improving the waterproof performance of artificial stone slabs. This reduces the outward precipitation and penetration of soluble salts under the action of rainwater, further preventing the occurrence of efflorescence.

[0072] The bottom layer is provided with a stainless steel profile, which 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.

[0073] When external forces are applied to the artificial stone slab, the stainless steel mesh responds quickly, dispersing concentrated stress over a wider area, thus preventing damage caused by excessive localized stress. The stainless steel profile continues to transfer the dispersed stress from the artificial stone slab towards the wall, further dispersing and absorbing this stress in the process.

[0074] Therefore, the fixed connection between stainless steel profiles and stainless steel mesh enhances the structural strength of the artificial stone slab, improves its flexural strength, and effectively disperses stress that might otherwise be concentrated in a certain area of ​​the artificial stone slab to the entire wall system, thereby avoiding the risk of local damage or even complete detachment of the artificial stone slab.

[0075] Moreover, the artificial stone slabs in this solution can be installed on the wall using a dry-hanging method, which simplifies the construction process and reduces the time and labor costs of wet work.

[0076] A method for preparing a high-toughness, efflorescence-resistant artificial stone slab, for preparing the high-toughness, efflorescence-resistant artificial stone slab as described in claim 9, comprising the following steps:

[0077] S1. Preparation of the base slurry: Mix the formulated amount of aluminosilicate mineral materials, cement and water evenly to obtain a mixture; add the formulated amount of quartz sand to the mixture, mix evenly, then add the composite fiber and stir evenly.

[0078] S2. Preparation of surface slurry: Mix the formulated amounts of aluminosilicate mineral materials, porous materials, cement, water and quartz sand evenly.

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

[0080] Pour the bottom layer of slurry into the mold, ensuring it covers the stainless steel mesh; after flattening and pre-pressing, pour the top layer of slurry into the mold, and then vibrate and press to obtain the artificial stone slab.

[0081] S4. A waterproofing agent is sprayed onto the surface of the artificial stone slab.

[0082] This preparation method can produce an artificial stone slab that is resistant to efflorescence, has high flexural strength, and high toughness. It is worth noting that during the preparation of the base slurry, after the basic raw materials such as aluminosilicate minerals, cement, water, and quartz sand have been thoroughly mixed, the composite fibers are slowly added while continuing to stir. This ensures that the fiber material is evenly dispersed in the base slurry, thereby enhancing the structural strength of the base layer.

[0083] Furthermore, the inclusion of stainless steel mesh and profiles in this design allows the artificial stone slabs to be dry-hung onto the wall, effectively eliminating the need for drilling holes and simplifying the construction process. This also significantly reduces the risk of cracks in the artificial stone slabs leading to breakage during subsequent use.

[0084] The present invention will be further illustrated below with reference to embodiments and comparative examples.

[0085] Examples 1-4

[0086] Prepare the materials according to the corresponding materials listed in Table 1 below, and follow the steps below to prepare a high-toughness, efflorescence-resistant artificial stone slab as described in Examples 1-4.

[0087] A method for preparing a highly resilient, efflorescence-resistant artificial stone slab includes the following steps:

[0088] S1. Preparation of the base slurry: By weight, mix 7-13 parts of aluminosilicate mineral material, 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 evenly.

[0089] S2. Preparation of surface slurry: Mix 7-13 parts of siliceous aluminous mineral material, 2-7 parts of porous material, 50-100 parts of cement, 8-15 parts of water and 120-210 parts of quartz sand evenly.

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

[0091] Pour the bottom layer of slurry into the mold, ensuring it covers the stainless steel mesh; after flattening and pre-pressing, pour the top layer of slurry into the mold, and then vibrate and press to obtain the artificial stone slab.

[0092] S4. A waterproofing agent is sprayed onto the surface of the artificial stone slab. The waterproofing agent is one or a combination of several of the following: a hydrophobic plug, a penetrating crystallizing agent, and a fluorocarbon coating agent.

[0093] The composite fiber comprises 2 parts stainless steel fiber, 0.1 parts calcium carbonate whiskers, and 0.2 parts synthetic fiber. The synthetic fiber is one or more of PVA fiber, PE fiber, PP fiber, and POM fiber. The aluminosilicate mineral material is one or more of metakaolin, silica fume, and silica powder. The porous material is zeolite powder and diatomaceous earth.

[0094] The stainless steel fibers include fine stainless steel fibers and coarse stainless steel fibers; the coarse stainless steel fibers have a length of 6-15 mm and a diameter of 200-600 μm; the fine stainless steel fibers have a length of 6-15 mm and a diameter of 45-190 μm; the calcium carbonate whiskers have an aspect ratio of 40-60; and the synthetic fibers have a length of 3-19 mm and a diameter of 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] The ratio 1 is basically the same as that of Example 4, except that: S3, the bottom slurry is transferred to the template and spread to form the bottom layer, and no stainless steel profile is placed in the mold; the bottom slurry is poured into the mold, spread and pre-pressed, and then the surface slurry is poured into the mold and vibrated to obtain the artificial stone slab.

[0101] Comparative Example 2

[0102] Example 2 is basically the same as Example 4, except that: S4, no waterproofing agent is sprayed on the surface of the artificial stone slab.

[0103] Comparative Example 3

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

[0105] Comparative Example 4

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

[0107] The artificial stone slabs prepared in the above embodiments and comparative examples were placed in a standard curing room with a temperature of 20±2℃ and a humidity of greater than 95% for 28 days. The surface efflorescence phenomenon of the artificial stone slab products was observed and recorded. The flexural strength and compressive strength of the artificial stone slabs prepared in the above embodiments and comparative examples after 28 days were tested using the test method of "GB / T 28635-2012 Concrete Pavement Bricks". The specific test results are shown in Table 2.

[0108] Table 2. Test results of relevant performance of artificial stone slabs

[0109]

[0110]

[0111] As can be seen from the test results in Table 2, the artificial stone slabs prepared in Examples 1-4 of this application have high flexural strength and compressive strength, and have the effect of resisting efflorescence. This indicates that the artificial stone slabs produced using the formula and preparation method of this application can improve their own defect of being prone to efflorescence while increasing strength, and can solve the risk of 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 subjected to external force, the stress in the artificial stone product prepared in Comparative Example 1 concentrates at a single point, leading to cracking or damage. Therefore, the flexural and compressive strengths of the artificial stone product prepared in Comparative Example 1 are inferior to 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 waterproofing agent, resulting in poor waterproofing performance of the artificial stone surface. In this case, soluble salts are released and seep out under the influence of rainwater, leading to efflorescence. Therefore, the preparation method of Comparative Example 2 cannot solve the problem of efflorescence in traditional artificial stone.

[0114] The difference between Comparative Example 3 and Example 4 is that Comparative Example 3 only used coarse stainless steel fibers. Coarse stainless steel fibers have a higher density, generally much higher than that of the polymer emulsion. During the mixing process, due to gravity, the stainless steel fibers tend to sink, while the polymer emulsion, being relatively lighter, tends to float, resulting in stratification in the slurry and making it difficult to maintain uniform mixing. In this case, the coarse stainless steel fibers and polymer emulsion are difficult to mix to form a uniform and stable slurry, thus failing to form a three-dimensional network structure. When the bottom layer is subjected to external forces, localized 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 product prepared in Comparative Example 3 are inferior to those of the artificial stone product prepared in Example 4.

[0115] Furthermore, the combination of various fiber materials and polymer emulsions not only improves the density of the underlying slurry and effectively reduces microcracks, thus reducing the channels for the penetration of moisture and harmful substances and helping to prevent efflorescence. In Comparative Example 3, the use of only coarse stainless steel fibers and polymer emulsions fails to improve the density of the underlying slurry, resulting in microcracks in the finished artificial stone, creating channels for the penetration of moisture and harmful substances, and consequently causing efflorescence. Therefore, the preparation method in Comparative Example 3 cannot solve the problem of efflorescence in traditional artificial stone.

[0116] The difference between Comparative Example 4 and Example 4 lies in the lack of adsorption of alkaline substances by porous materials in Comparative Example 4, leading to the accumulation of alkaline substances on the surface layer and causing efflorescence. Furthermore, the synergistic effect of the aluminosilicate mineral material and the porous material fills the pore structure within the surface layer, improving both its density and strength. The lack of this synergistic effect in Comparative Example 4 results in poorer internal bonding of the artificial stone product compared to that of Example 4. Therefore, the flexural and compressive strength of the artificial stone product prepared in Comparative Example 4 are inferior to those in Example 4, and the preparation method of Comparative Example 4 cannot solve the problem of efflorescence in traditional artificial stone.

[0117] The technical principles of the present invention have been described above with reference to specific embodiments. These descriptions are merely for explaining the principles of the invention and should not be construed as limiting the scope of protection of the invention in any way. Based on this explanation, those skilled in the art can readily conceive of other specific embodiments of the invention without inventive effort, and these embodiments will all fall within the scope of protection of the present invention.

Claims

1. A high-toughness, efflorescence-resistant artificial stone slab, characterized in that, It includes a base layer and a top layer; the base 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 fiber and 8-15 parts of water. The raw materials for 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. By weight, the composite fiber comprises 1.5-2.0 parts stainless steel fiber, 0.1-0.3 parts calcium carbonate whiskers, and 0.1-0.2 parts synthetic fiber.

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

3. The high-toughness, efflorescence-resistant artificial stone slab according to claim 1, characterized in that, The stainless steel fibers include fine stainless steel fibers and coarse stainless steel fibers; The coarse stainless steel fibers have a length of 6-15 mm and a diameter of 200-600 μm; The fine stainless steel fibers have a length of 6-15 mm and a diameter of 45-190 μm; The aspect ratio of the calcium carbonate whiskers is 40-60; The synthetic fiber has a length of 3-19 mm and a diameter of 45-190 μm.

4. The high-toughness, efflorescence-resistant artificial stone slab according to claim 1, characterized in that, The silicoaluminous mineral material is one or more of metakaolin, silica fume, and silica powder.

5. The high-toughness, efflorescence-resistant artificial stone slab according to claim 4, characterized in that, The porous material is zeolite powder and diatomaceous earth.

6. The high-toughness, efflorescence-resistant artificial stone slab according to claim 1, characterized in that, By weight, the quartz sand comprises 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.

7. The high-toughness, efflorescence-resistant artificial stone slab according to claim 1, characterized in that, The surface of the artificial stone slab is sprayed with a waterproofing agent, which is one or a combination of several of the following: hydrophobic plugs, penetrating crystallizers, and fluorocarbon coating agents.

8. The high-toughness, efflorescence-resistant artificial stone slab according to claim 7, characterized in that, The bottom layer is provided with a stainless steel profile, which 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.

9. A method for preparing a high-toughness, efflorescence-resistant artificial stone slab, characterized in that, The method for preparing a high-toughness, efflorescence-resistant artificial stone slab as described in claim 8 includes the following steps: S1. Preparation of the base slurry: Mix the formulated amount of aluminosilicate mineral materials, cement and water evenly to obtain a mixture; add the formulated amount of quartz sand to the mixture, mix evenly, then add the composite fiber and stir evenly. S2. Preparation of surface slurry: Mix the formulated amounts of aluminosilicate mineral materials, porous materials, cement, water and quartz sand evenly; S3. Transfer the bottom slurry to the template and spread it flat to form the bottom layer. Place a stainless steel mesh with welded stainless steel profiles inside the mold. Pour the bottom layer of slurry into the mold, ensuring it covers the stainless steel mesh; after flattening and pre-pressing, pour the top layer of slurry into the mold, and then vibrate and press to obtain the artificial stone slab. S4. A waterproofing agent is sprayed onto the surface of the artificial stone slab.

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