Lightweight high-toughness dry-hanging artificial stone slab and preparation method thereof

Abstract

The invention discloses a light high-toughness dry-hanging artificial stone slab and a preparation method thereof.The light high-toughness dry-hanging artificial stone slab comprises an artificial stone slab body and a stainless steel profile, the stainless steel profile is embedded in the artificial stone slab body, and the mounting end of the stainless steel profile extends out of the artificial stone slab body; the mounting end of the stainless steel profile is used for connecting the artificial stone plate and fixedly mounting the artificial stone plate and a wall body; the artificial stone plate is formed by mixing a plurality of different slurries, and the slurries comprise the following components in parts by weight: 80-100 parts of cement, 10-30 parts of silica fume, 30-40 parts of mineral powder, 30-40 parts of quartz powder, 1-1.5 parts of mixed fibers, 80-120 parts of aggregate, 0.5-2 parts of pigment, 50-60 parts of a water reducing agent and 9-12 parts of an auxiliary agent. The artificial stone plate also has the advantages of light weight, high toughness, high breaking strength and the like, and the condition that the artificial stone plate is broken after a long time is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of dry - hung artificial stone slabs, and particularly to a lightweight and high - toughness dry - hung artificial stone slab and a preparation method thereof. Background Art

[0002] In the field of building decoration, natural rhyolitic rocks have long been favored due to their unique textures, rich color levels, and excellent weather resistance, and have become one of the preferred materials for high - end interior and exterior wall finishes.

[0003] However, natural stones generally have the problem of relatively large brittleness. This means that when subjected to external forces, the stones are more likely to break, with relatively low flexural strength and insufficient toughness. This characteristic is particularly prominent in the exterior wall decoration of buildings that need to withstand external factors such as wind pressure and temperature changes. Especially in the pursuit of lightweight and modern dry - hung structure designs, natural stones are difficult to meet the requirements of safety and stability due to their high brittleness and low toughness, increasing the construction difficulty and post - maintenance costs.

[0004] Secondly, the weight of natural stones is another problem that cannot be ignored. Compared with artificial materials, natural stones have a large density and heavy mass, which not only increases the difficulty of transportation and installation but also places higher requirements on the load - bearing structure of buildings. In the decoration of high - rise buildings or large public facilities, the extensive use of natural stones may cause excessive structural loads, affecting the overall safety and stability of the building. In addition, under the long - term action of gravity and external environmental factors (such as weathering and corrosion), the connectors between the stones and the wall may gradually loosen, increasing the risk of stone detachment and posing a potential threat to personal and property safety. Summary of the Invention

[0005] The purpose of the present invention is to propose a lightweight and high - toughness dry - hung artificial stone slab. The artificial stone slab can be installed on the wall through the installation end of a stainless - steel profile. The stainless - steel profile can ensure a firm connection between the artificial stone slab and the wall, improve the installation efficiency of the artificial stone slab, reduce the installation difficulty, and avoid the situation of the artificial stone slab cracking due to installation operations such as drilling during the installation process.

[0006] Another purpose of the present invention is to propose a preparation method of a lightweight and high - toughness dry - hung artificial stone slab, which prepares an artificial stone slab with a rhyolite pattern. The artificial stone slab also has the advantages of being lightweight, high - toughness, and having a large flexural strength, reducing the situation of the artificial stone slab breaking after long - term use.

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

[0008] A lightweight and highly ductile dry-hanging artificial stone slab, comprising an artificial stone slab and a stainless steel profile. The stainless steel profile is embedded in the artificial stone slab, and the installation end of the stainless steel profile extends out of the artificial stone slab. The installation end of the stainless steel profile is used to connect the artificial stone slab to the wall for fixed installation;

[0009] The artificial stone slab is made of a mixture of various different slurries. By weight, the slurry includes 80 - 100 parts of cement, 10 - 30 parts of silica fume, 30 - 40 parts of mineral powder, 30 - 40 parts of quartz powder, 1 - 1.5 parts of mixed fiber, 80 - 120 parts of aggregate, 0.5 - 2 parts of colorant, 50 - 60 parts of water reducer, and 9 - 12 parts of additive.

[0010] Furthermore, the stainless steel profile includes a mesh and connectors. The first ends of the multiple connectors are fixedly connected to the outer edge of the mesh. The stainless steel mesh is embedded in the artificial stone slab, and the ends of the connectors pass through the artificial stone slab.

[0011] Furthermore, by weight, the mixed fiber includes 0.05 - 0.1 parts of mineral fiber, 0.1 - 0.2 parts of organic fiber, and 0.9 - 1.2 parts of whisker.

[0012] Furthermore, the mineral fiber is one or a combination of glass fiber, basalt fiber, and wollastonite fiber. The diameter of the mineral fiber is 0.02 - 0.5 mm, and the length is 3 - 18 mm.

[0013] Furthermore, the synthetic fiber is one or a combination of UPE fiber, POM fiber, PP fiber, and PVA fiber.

[0014] Furthermore, the whisker is one or a combination of calcium carbonate whisker, calcium sulfate whisker, and potassium titanate whisker. The aspect ratio of the whisker is 40 - 60.

[0015] Furthermore, by weight, the additive includes 8 - 10 parts of polymer emulsion, 0.7 - 0.9 parts of defoamer, and 0.1 - 0.2 parts of viscosity regulator.

[0016] Furthermore, by weight, the slurry also includes 0.001 - 0.1 parts of nano zinc salt.

[0017] Furthermore, by weight, the aggregate includes 5 - 15 parts of 16 - 26 mesh quartz sand, 40 - 60 parts of 26 - 40 mesh quartz sand, 5 - 10 parts of 40 - 70 mesh quartz sand, and 30 - 40 parts of 70 - 120 mesh quartz sand.

[0018] Furthermore, the plastic viscosity μ value of the slurry is 150 - 300 Pa·s.

[0019] The preparation method of the above-mentioned lightweight and high-toughness dry-hanging artificial stone slab includes the following steps:

[0020] S1. Prepare slurries of multiple different colors: Mix the measured amounts of cement, silica fume, mineral powder, quartz powder, mixed fibers, aggregate, colorant, water reducer, additives, and nano-zinc salt to obtain slurries of multiple different colors, and mix multiple different raw materials to prepare a textured mixed slurry;

[0021] S2. Pour the mixed slurry into a mold pre-placed with stainless steel profiles through a specific cloth-feeding device, vibrate and press to obtain a slab, and cure the slab to obtain a lightweight and high-toughness dry-hanging artificial stone slab.

[0022] Compared with the prior art, the technical solution proposed by the present invention can have the following beneficial effects:

[0023] 1. The artificial stone slab can be installed on the wall through the installation end of the stainless steel profile. The stainless steel profile can ensure a firm connection between the artificial stone slab and the wall, improve the installation efficiency of the artificial stone slab, reduce the installation difficulty, and avoid the situation that the artificial stone slab is broken due to installation operations such as drilling during the installation process;

[0024] 2. By mixing various raw materials such as cement and mixed fibers, a lightweight and high-toughness artificial stone slab is formed, solving the problem that traditional natural stones are prone to cracks after long-term use due to their large mass.

[0025] 3. By controlling the plastic viscosity μ value of the slurry, the artificial stone slab has a more uniform structure and performance after curing, improving the quality indexes in terms of its strength, durability, impermeability, etc. Moreover, the slurry has good fluidity and can be well integrated with slurries of different colors during the flowing process, thereby shaping delicate textures and obtaining an artificial stone product with clear textures. Description of the Drawings

[0026] Figure 1 is a schematic diagram of a lightweight and high-toughness dry-hanging artificial stone slab of the present invention;

[0027] Among them, 1. Artificial stone slab; 2. Stainless steel profile; 21. Mesh; 22. Connector. Detailed Embodiments

[0028] The technical solution of the present invention will be further described below in conjunction with the detailed embodiments.

[0029] The present invention provides a lightweight and high-toughness dry-hanging artificial stone slab and its preparation method.

[0030] A lightweight and highly ductile dry-hanging artificial stone slab, comprising an artificial stone slab and a stainless steel profile. The stainless steel profile is embedded in the artificial stone slab, and the installation end of the stainless steel profile extends out of the artificial stone slab. The installation end of the stainless steel profile is used to connect the artificial stone slab to the wall for fixed installation.

[0031] The artificial stone slab is made by mixing a variety of different slurries. By weight, the slurries include 80 - 100 parts of cement, 10 - 30 parts of silica fume, 30 - 40 parts of mineral powder, 30 - 40 parts of quartz powder, 1 - 1.5 parts of mixed fiber, 80 - 120 parts of aggregate, 0.5 - 2 parts of coloring agent, 50 - 60 parts of water reducing agent, and 9 - 12 parts of additives.

[0032] Silica fume has extremely high activity and can react with the hydration products of cement, thereby filling the pores of the artificial stone slab, increasing the matrix density and strength, and significantly improving the strength and durability of the artificial stone slab. Mineral powder has a certain cementitious activity and can participate in the hydration reaction when acting together with cement and silica fume, generating hydration products with cementitious ability. These hydration products can firmly bond a variety of raw materials together to form a solid whole, which can improve the strength and durability of the artificial stone slab. At the same time, the mineral powder can fill the voids between the aggregates and tightly bond the aggregates together through cementitious action, thereby improving the strength of the artificial stone slab and reducing the relative movement between the aggregates, thus enhancing the stability and durability of the artificial stone slab.

[0033] An appropriate amount of mixed fiber is evenly mixed in the slurry, which can increase the tensile strength and toughness of the artificial stone slab, effectively prevent the expansion of cracks in the artificial stone slab, absorb energy, and improve the impact resistance and crack resistance of the artificial stone slab. When the artificial stone slab is subjected to external forces, the uniformly dispersed mixed fiber can play its reinforcing role, making the artificial stone slab not easily break and maintaining good integrity.

[0034] An appropriate amount of water reducing agent can significantly improve the workability of the mortar, increase the plasticity of the mortar, ensure that the plasticity of the slurry is maintained within a specific range, so that after a variety of slurries are mixed together, an artificial stone slab with random flow pattern texture can be formed. The water reducing agent can promote the hydration reaction of cement and make it proceed more fully. At the same time, the water reducing agent can also reduce the pores and cracks in the artificial stone slab, improve its density, thereby increasing the late strength of the artificial stone slab and enhancing the strength and durability of the artificial stone slab.

[0035] In addition, in this solution, by selecting different coloring agents, various colors can be given to the artificial stone slab, and after mixing a variety of slurries with different colors, an artificial stone slab with a random flow pattern can be formed.

[0036] Therefore, by mixing various raw materials such as cement, silica fume, and slag powder, a lightweight and highly ductile artificial stone slab is formed, solving the problem that traditional natural stones are prone to cracks after long-term use due to their relatively large mass. In addition, stainless steel profiles are embedded in the artificial stone slab, providing a strong internal framework for the artificial stone slab. Stainless steel has high strength and excellent corrosion resistance, which can effectively disperse various stresses borne by the artificial stone slab during use, preventing problems such as cracking and deformation of the artificial stone slab, and greatly improving the overall structural stability of the artificial stone slab. Moreover, the installation ends of the stainless steel profiles extend out of the artificial stone slab, facilitating the connection and fixed installation of the artificial stone slab to the wall, and avoiding damage to the artificial stone slab that may occur in traditional installation methods. Also, when the artificial stone slab is subjected to external forces, the stainless steel profiles can quickly disperse the stress to the wall, further improving the flexural strength of the artificial stone slab and solving problems such as cracking and deformation that are prone to occur in traditional artificial stone slabs.

[0037] The stainless steel profile 2 includes a mesh 21 and a connecting member 22. The first ends of the plurality of connecting members 22 are fixedly connected to the outer edge of the mesh 21, and the stainless steel mesh 21 is embedded in the artificial stone slab, and the second ends of the connecting members 22 penetrate through the artificial stone slab.

[0038] The stainless steel profile 2 is composed of a mesh 21 and a connecting member 22. The mesh 21, as an important support structure, has a regular grid pattern, providing a stable internal framework for the entire artificial stone slab. The first ends of the plurality of connecting members 22 are fixedly connected to the outer edge of the mesh 21 in a firm manner, ensuring a tight and reliable connection between the two.

[0039] First of all, the stainless steel material has excellent strength and toughness, which can effectively disperse various stresses received by the artificial stone slab during use. When the artificial stone slab is faced with external pressure, impact force or other forms of acting forces, the stainless steel mesh 21 can evenly disperse these stresses to each part, avoiding stress concentration at a certain place and causing the artificial stone slab to crack or be damaged. Secondly, this structure greatly enhances the flexural performance of the artificial stone slab. Whether it is subjected to bending force or other forces that may cause breakage, the stainless steel mesh 21 can provide strong support for the artificial stone slab, enabling it to withstand greater loads without breaking.

[0040] In addition, the second ends of the connecting members 22 penetrate through the artificial stone slab, and the staff can use fixing parts such as screws to install the second ends of the connecting members 22 on the wall, completing the installation of the artificial stone slab without drilling holes in the artificial stone slab, which not only ensures the integrity of the artificial stone slab but also makes the installation process more simple and fast.

[0041] By weight, the mixed fibers include 0.05 - 0.1 part of mineral fiber, 0.1 - 0.2 part of organic fiber, and 0.9 - 1.2 parts of whiskers.

[0042] Under a specific formula, after the three materials of mineral fiber, organic fiber and whisker are mixed, they form a uniform network structure in the artificial stone matrix, and play their respective advantages to produce a synergistic reinforcement effect. Mineral fiber can improve the tensile strength and high temperature resistance of artificial stone slabs, whiskers can enhance the strength and rigidity of artificial stone slabs, and organic fiber can improve the toughness and impact resistance of artificial stone slabs. Therefore, the three cooperate with each other to jointly improve the comprehensive performance of artificial stone slabs.

[0043] Moreover, the hybrid fiber has better dispersion in the matrix material and forms a complex three-dimensional network structure in the artificial stone board, so that it can participate in the reaction more evenly, optimize the microstructure of the artificial stone board, effectively disperse stress, improve the strength and toughness of the artificial stone board, and reduce the porosity of the artificial stone board, and improve the density and durability of the artificial stone board. In contrast, due to the high density of traditional stainless steel fibers, local aggregation may occur during the stirring process, affecting the uniformity of the reaction.

[0044] Due to the synergistic reinforcement of mineral fibers, organic fibers and whiskers, as well as the optimization of the microstructure, the flexural strength of artificial stone slabs has been further improved, so that artificial stone slabs can withstand greater bending forces during use and are less likely to break, thereby improving the reliability and safety of artificial stone slabs.

[0045] The mineral fiber is a combination of one or more of glass fiber, basalt fiber and wollastonite fiber. The mineral fiber has a diameter of 0.02-0.5 mm and a length of 3-18 mm.

[0046] Compared with traditional steel fibers, the mineral fibers selected in this solution have the advantage of relatively low density. Adding them to artificial stone slabs can reduce the overall weight of the artificial stone slabs to a certain extent and achieve lightweighting.

[0047] Moreover, glass fiber, basalt fiber and wollastonite fiber all have high tensile strength, bending strength and compressive strength. When glass fiber, basalt fiber and wollastonite fiber are added to artificial stone panels, they can form a strong reinforcement network inside the artificial stone panels. When subjected to external forces, mineral fibers can bear part of the load, effectively disperse stress, increase the toughness of the artificial stone panels, and thus improve the overall strength of the artificial stone panels.

[0048] In addition, the diameter and length range of the mineral fibers are limited in this solution, which can better disperse the mineral fibers and make them evenly mixed in the slurry of the artificial stone board, thereby improving the fluidity of the slurry, reducing the generation of pores and defects, and improving the quality and yield of the artificial stone board.

[0049] The synthetic fiber is one or a combination of more than one of UPE fiber, POM fiber, PP fiber, and PVA fiber.

[0050] Synthetic fibers such as UPE fiber, POM fiber, PP fiber, and PVA fiber all have the advantage of high ductility, which can improve the overall strength of the artificial stone slab. When the artificial stone slab is subjected to external forces, the synthetic fiber can share part of the load through its own deformation, thereby reducing the burden on other materials and improving the strength and load-bearing capacity of the artificial stone slab. When microcracks appear inside the artificial stone slab, the synthetic fiber can cross the crack and form a stress concentration area at the crack tip, thereby suppressing the crack propagation, reducing the generation and development of cracks, and maintaining the integrity and stability of its structure.

[0051] In addition, the density of the synthetic fiber is much lower than that of the steel fiber. Therefore, the addition of the synthetic fiber can achieve light weight while improving the quality of the artificial stone slab; during the mixing process of the slurry, the synthetic fiber will not quickly precipitate or agglomerate due to the action of gravity, so it can better interact with the matrix to form a good interfacial bond, improving the overall performance of the artificial stone slab, including flexural strength, durability, etc.

[0052] The whisker is one or a combination of more than one of calcium carbonate whisker, calcium sulfate whisker, and potassium titanate whisker, and the aspect ratio of the whisker is 40 - 60.

[0053] Among them, the whiskers selected in this solution have relatively high mechanical strength. When added to the slurry, they can enhance the compressive strength and flexural strength of the artificial stone slab to meet the usage requirements of the artificial stone slab.

[0054] Moreover, whiskers with an aspect ratio in a specific range are more likely to be evenly dispersed in the slurry of the artificial stone slab, ensuring the performance consistency of each part of the artificial stone slab, improving the overall stability of the artificial stone slab, avoiding the appearance of local weak points, and reducing performance fluctuations caused by uneven microstructure.

[0055] By weight, the auxiliary agent includes 8 - 10 parts of polymer emulsion, 0.7 - 0.9 parts of defoaming agent, and 0.1 - 0.2 parts of viscosity regulator.

[0056] Among them, adding polymer emulsion to the formula, the polymer emulsion increases the bonding force of the aggregate interfacial transition zone and cures in the cement to form a fiber network structure, thereby increasing the toughness of the artificial stone slab.

[0057] By adding a defoaming agent, the bubbles in the slurry can be eliminated, reducing the porosity of the artificial stone slab, thereby improving the mechanical properties such as strength, hardness, and wear resistance of the artificial stone slab.

[0058] In addition, in order to fix the artificial stone slurry of this solution at a specific viscosity, an appropriate amount of viscosity regulator is added to the slurry to ensure that the slurries of multiple different colors will not stratify after mixing.

[0059] By weight, the slurry further includes 0.001 - 0.1 parts of nano zinc salt.

[0060] After the nano zinc salt is added, the nano zinc ions can react with calcium hydroxide in the cement hydration products. The specific reaction process is that the zinc ions combine with the hydroxide ions in calcium hydroxide to form compounds such as zinc hydroxide. Zinc hydroxide can fill the pores in the cement to form crystals, increasing the bonding force between cement particles, making the artificial stone slab more dense, and further enhancing the strength of the artificial stone slab.

[0061] By weight, the aggregate includes 5 - 15 parts of 16 - mesh to 26 - mesh quartz sand, 40 - 60 parts of 26 - mesh to 40 - mesh quartz sand, 5 - 10 parts of 40 - mesh to 70 - mesh quartz sand, and 30 - 40 parts of 70 - mesh to 120 - mesh quartz sand.

[0062] The mixed use of quartz sands with multiple particle sizes enables the formation of a multi - level structure inside the artificial stone slab. This structure can better disperse and absorb stress when subjected to external forces, thereby improving the toughness and impact resistance of the slab.

[0063] Specifically, the larger - particle quartz sand plays a major supporting role when bearing pressure, while the smaller - particle quartz sand can absorb energy through deformation and displacement, thereby improving the toughness of the artificial stone slab, making the artificial stone slab not easily brittle - damaged when subjected to impact or vibration, and improving its service life and safety.

[0064] The plastic viscosity μ value of the slurry is 150 - 300 Pa·s.

[0065] When the plastic viscosity μ value is within a suitable range, the slurries of multiple different colors can maintain good stability. During the flow process, it will neither be too thin to lose control of the texture formation nor too viscous to be difficult to shape delicate textures, thus obtaining a mixed slurry with textures and preparing an artificial stone finished product with clear textures. Moreover, the artificial stone slab with the plastic viscosity within a suitable range has a more uniform structure and performance after curing, improving its quality indicators in terms of strength, durability, impermeability, etc.

[0066] A preparation method of a lightweight and high - toughness dry - hanging artificial stone slab includes the following steps:

[0067] S1. Prepare slurries of multiple different colors: Mix the cement, silica fume, blast furnace slag powder, quartz powder, mixed fibers, aggregate, colorant, water reducer, additives, and nano zinc salt in the formula amounts to obtain slurries of multiple different colors, and mix multiple different raw materials to prepare a textured mixed slurry;

[0068] S2. Pour the mixed slurry into a mold pre-placed with stainless steel profiles 2 through a specific cloth device, vibrate and press to obtain a plate, and cure the plate to obtain a lightweight and highly tough dry-hanging artificial stone slab.

[0069] Among them, by mixing various raw materials, slurries of different colors and with viscosities within a specific range can be prepared. According to actual needs, a mixed slurry can be prepared to obtain an artificial stone slab with a flow pattern. This artificial stone slab also has the advantages of being lightweight, highly tough, and having a large flexural strength.

[0070] Moreover, stainless steel profiles 2 are pre-embedded in the artificial stone slab. The stainless steel profiles 2 can further enhance the overall strength of the artificial stone slab, better improve the bearing capacity and anti-deformation ability of the artificial stone slab, and further reduce the occurrence of fractures in the artificial stone slab after long-term use. In addition, the artificial stone slab can be installed on the wall through the installation end of the stainless steel profiles 2. The stainless steel profiles 2 can ensure a firm connection between the artificial stone slab and the wall, improve the installation efficiency of the artificial stone slab, reduce the installation difficulty, and avoid the situation of the artificial stone slab being broken due to installation operations such as drilling during the installation process.

[0071] The present invention will be further elaborated below with reference to examples and comparative examples.

[0072] Example 1

[0073] Prepare materials corresponding to each raw material listed in Table 1 below, and prepare a lightweight and highly tough dry-hanging artificial stone slab of Examples 1-4 according to the following steps.

[0074] A lightweight and highly tough dry-hanging artificial stone slab includes the following steps:

[0075] S1. Prepare slurries of multiple different colors: By weight, mix 80-100 parts of cement, 10-30 parts of silica fume, 30-40 parts of blast furnace slag powder, 30-40 parts of quartz powder, 1-1.5 parts of mixed fibers, 80-120 parts of aggregate, 0.5-2 parts of colorant, 50-60 parts of water reducer, 9-12 parts of additives, and 0.001-0.1 parts of nano zinc salt to obtain slurries of multiple different colors, and mix multiple different raw materials to prepare a textured mixed slurry;

[0076] S2. Prepare stainless steel profiles 2: Weld multiple connectors 22 to the outer edge of the mesh 21;

[0077] S3. Pour the mixed slurry into a mold pre-placed with stainless steel profiles through a specific cloth device, vibrate and press to obtain a plate, and cure the plate to obtain a lightweight and highly ductile dry-hanging artificial stone slab.

[0078] Among them, the mixed fibers include 0.05 - 0.1 parts of mineral fibers, 0.1 - 0.2 parts of synthetic fibers, and 0.9 - 1.2 parts of whiskers. The mineral fibers are a combination of glass fiber, basalt fiber, and wollastonite fiber, the diameter of the mineral fibers is 0.02 - 0.5 mm, and the length is 3 - 18 mm. The synthetic fibers are a combination of UPE fiber, POM fiber, PP fiber, and PVA fiber. The whiskers are a combination of calcium carbonate whiskers, calcium sulfate whiskers, and potassium titanate whiskers, and the aspect ratio of the whiskers is 40 - 60. The additives include 9 parts of polymer emulsion, 0.8 parts of defoamer, and 0.1 - 0.2 parts of viscosity regulator.

[0079] The aggregate includes 5 - 15 parts of 16 - 26 mesh quartz sand, 40 - 60 parts of 26 - 40 mesh quartz sand, 5 - 10 parts of 40 - 70 mesh quartz sand, and 30 - 40 parts of 70 - 120 mesh quartz sand. The plastic viscosity μ value of the slurry is 150 Pa·s - 300 Pa·s.

[0080] Table 1

[0081]

[0082] Comparative Example 1

[0083] Comparative Example 1 is basically the same as Example 4, except that: S3. No stainless steel profiles are placed in the mold, the mixed slurry is poured into the pre-mold through a specific cloth device, vibrated and pressed to obtain a plate, and the plate is cured to obtain a lightweight and highly ductile dry-hanging artificial stone slab.

[0084] Comparative Example 2

[0085] Comparative Example 2 is basically the same as Example 4, except that: Equal weight parts of stainless steel fibers are used instead of the mixed fibers.

[0086] Comparative Example 3

[0087] Comparative Example 3 is basically the same as Example 4, except that: The plastic viscosity μ value of the slurry is 400 Pa·s.

[0088] Comparative Example 4

[0089] Comparative Example 4 is basically the same as Example 4, except that: Equal weight parts of ore fibers are used instead of the mixed fibers.

[0090] Comparative Example 5

[0091] Comparative Example 4 is basically the same as Example 4, except that: by weight, the mixed fibers include 1.2 parts of mineral fibers, 0.05 parts of organic fibers and 0.1 part of whiskers.

[0092] The artificial stones prepared from the above examples and comparative examples were tested for self-weight, flexural strength and compressive strength. Among them, the test methods of "GB / T 28635-2012 Concrete Pavement Bricks" were used to test the flexural strength and compressive strength, and the specific test results are shown in Table 2.

[0093] Table 2

[0094]

[0095] 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 light self-weight, indicating that the artificial stone slabs produced by using the formula and preparation method of the present application can improve the defect of heavy self-weight while increasing the strength, and can solve the risk of easy fracture of traditional artificial stone slabs after long-term use.

[0096] The difference between Comparative Example 1 and Example 4 is that: the finished artificial stone prepared in Comparative Example 1 lacks stainless steel profiles, so the self-weight of the finished artificial stone is lighter than that of the artificial stone in Example 4, and the corresponding flexural strength and compressive strength are both reduced to a certain extent. Therefore, when the finished artificial stone prepared in Comparative Example 1 is subjected to external force, stress is concentrated at a certain place, resulting in cracking or damage of the artificial stone slab.

[0097] The difference between Comparative Example 2 and Example 4 is that: Comparative Example 2 uses equal weight parts of stainless steel fibers instead of mixed fibers. Due to reasons such as large density, the gravity acting on the stainless steel fibers is stronger, and the stainless steel fibers are prone to sink in the system, so local aggregation may occur during stirring and other processes, affecting the uniformity of the reaction. When the finished artificial stone is stressed, the fiber distribution in the aggregation area is too dense, while the fiber distribution in the surrounding area is relatively less, so that the stress cannot be evenly transmitted and dispersed through the fibers, but is concentrated in the stainless steel fiber aggregation area, which is easy to cause cracks in these parts, thereby reducing the local flexural strength of the artificial stone.

[0098] The difference between Comparative Example 3 and Example 4 is that: the slurry in Comparative Example 3 is too viscous, making it difficult to stir various raw materials evenly, so that various raw materials cannot be evenly distributed in the slurry, and an effective reinforcing network structure cannot be formed. When stressed, the stress cannot be evenly transmitted and dispersed, and cracks are easily generated and propagated at weak parts, resulting in a significant reduction in the compressive strength, flexural strength, etc. of the finished artificial stone.

[0099] The difference between Comparative Example 4 and Example 4 is that the mixed fiber is replaced by the mineral fiber in equal weight. The mineral fiber is relatively less flexible. The use of mineral fiber alone may result in the artificial stone product having a weaker ability to absorb and dissipate energy when impacted or bent, and is prone to brittle fracture, and the overall toughness is not as good as the artificial stone product prepared in Example 4.

[0100] When mineral fibers, organic fibers and whiskers are mixed, different fibers can reinforce the artificial stone matrix in different directions and scales, forming a more complete reinforcement system. The morphology, structure and performance of mineral fibers are relatively simple, and it is difficult to strengthen artificial stone from multiple dimensions like mixed fibers. The effect of improving the compressive strength and flexural strength of artificial stone products may not be as good as that of artificial stone products prepared with mixed fibers.

[0101] The difference between Comparative Example 5 and Example 4 is that the reduction of whiskers and organic fibers and the excess of mineral fibers may destroy the synergistic effect between the fibers, so that the uniformity and stability of the internal structure of the artificial stone are affected. Among them, the content of organic fibers is greatly reduced, and organic fibers are the key component to provide flexibility. This will cause the artificial stone to significantly weaken its ability to absorb energy when impacted or bent, making it easier to break and lack toughness. It may be more prone to cracks and breakage in actual use. The whisker content is too low to form a sufficiently effective reinforcement network, and it is difficult to give full play to its advantages of high strength and high modulus to improve the strength of the artificial stone. In contrast, the compressive strength and flexural strength of the finished artificial stone prepared in Comparative Example 5 may be insufficient, and it cannot meet the application scenarios that require high strength.

[0102] 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 lightweight and high-toughness dry-hanging artificial stone slab, characterized in that: It comprises an artificial stone slab and a stainless steel profile, wherein the stainless steel profile is inlaid in the artificial stone slab, the mounting end of the stainless steel profile extends out of the artificial stone slab, and the mounting end of the stainless steel profile is used to connect the artificial stone slab to the wall for fixed installation; The artificial stone board is mixed with a variety of different slurries. By weight, the slurry includes 80-100 parts of cement, 10-30 parts of silica fume, 30-40 parts of mineral powder, 30-40 parts of quartz powder, 1-1.5 parts of mixed fiber, 80-120 parts of aggregate, 0.5-2 parts of colorant, 50-60 parts of water reducer and 9-12 parts of additives.

2. A lightweight and high-toughness dry-hanging artificial stone slab according to claim 1, characterized in that: The stainless steel profile comprises a mesh and connectors, the head ends of the multiple connectors are fixedly connected to the outer edges of the mesh, the stainless steel mesh is embedded in the artificial stone board, and the ends of the connectors pass through the artificial stone board.

3. The lightweight and high-toughness dry-hanging artificial stone slab according to claim 1 is characterized in that: In parts by weight, the mixed fiber comprises 0.05-0.1 parts of mineral fiber, 0.1-0.2 parts of organic fiber and 0.9-1.2 parts of whisker.

4. The lightweight and high-toughness dry-hanging artificial stone slab according to claim 3 is characterized in that: The mineral fiber is a combination of one or more of glass fiber, basalt fiber and wollastonite fiber. The mineral fiber has a diameter of 0.02-0.5 mm and a length of 3-18 mm.

5. The lightweight and high-toughness dry-hanging artificial stone slab according to claim 3 is characterized in that: The synthetic fiber is a combination of one or more of UPE fiber, POM fiber, PP fiber and PVA fiber; The whiskers are a combination of one or more of calcium carbonate whiskers, calcium sulfate whiskers, and potassium titanate whiskers, and the aspect ratio of the whiskers is 40-60.

6. The lightweight and high-toughness dry-hanging artificial stone slab according to claim 4 is characterized in that: In parts by weight, the auxiliary agent includes 8-10 parts of polymer emulsion, 0.7-0.9 parts of defoaming agent and 0.1-0.2 parts of viscosity regulator.

7. The lightweight and high-toughness dry-hanging artificial stone slab according to claim 1 is characterized in that: The slurry also includes 0.001-0.1 parts by weight of nano zinc salt.

8. The lightweight and high-toughness dry-hanging artificial stone slab according to claim 1 is characterized in that: In parts by weight, the aggregate includes 5-15 parts of 16-26 mesh quartz sand, 40-60 parts of 26-40 mesh quartz sand, 5-10 parts of 40-70 mesh quartz sand and 30-40 parts of 70-120 mesh quartz sand.

9. The lightweight and high-toughness dry-hanging artificial stone slab according to claim 7, characterized in that: The plastic viscosity μ value of the slurry is 150-300 Pa·s.

10. A method for preparing a lightweight and high-toughness dry-hanging artificial stone slab, characterized in that: The method for preparing a lightweight and high-toughness dry-hanging artificial stone slab according to any one of claims 7 to 9 comprises the following steps: S1. Preparing slurries of various colors: Mixing the formulated amounts of cement, silica fume, mineral powder, quartz powder, mixed fiber, aggregate, colorant, water reducing agent, additive and nano zinc salt to obtain slurries of various colors, and mixing various raw materials to prepare mixed slurries with textures; S2. The mixed slurry is poured into a mold with a stainless steel profile placed in advance through a specific distribution device, and a plate is obtained by vibration pressing. The plate is cured to obtain a light and high-toughness dry-hanging artificial stone plate.

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