Composition, artificial stone material, artificial stone structural member and preparation method thereof

Abstract

The invention relates to the technical field of artificial stone materials, in particular to a composition, an artificial stone material, an artificial stone structural member and a preparation method of the artificial stone structural member, and aims at preparing the artificial stone material which is light and has high impact performance. The invention discloses a composition of an artificial stone material. The composition comprises thermoplastic resin, expanded perlite filler and a surface modifier, wherein the particle size of the expanded perlite filler is 3 [mu] m-20 [mu] m, and / or the tap density of the expanded perlite filler is greater than or equal to 0.48 g / cm < 3 >; the surface modifier is used for modifying the surface of the expanded perlite filler, and the oil absorption value of the expanded perlite modified by the surface modifier is less than or equal to 150%.

Description

Technical Field

[0001] The present application relates to the technical field of artificial stone materials, and in particular to a composition, an artificial stone material, an artificial stone structural member and a preparation method thereof. Background Art

[0002] Artificial stone materials are compounded from polymer, cement or a mixture of the two as binding materials, natural stone powder or sand (such as powder or sand of natural quartz stone) or aluminum hydroxide powder as main materials, adding pigments and other auxiliaries through processes such as stirring and mixing, and condensation and curing. This artificial stone material has the characteristics of being hard (Mohs hardness is 5-7) and having a dense structure (density 2.2 g / cm 3 ~2.8g / cm 3 ). When it is applied to scenarios with relatively light weight requirements, it cannot meet the usage requirements.

[0003] In the related art, unsaturated polyester resin is combined with aluminum powder, calcium powder, etc. to prepare artificial stone materials. Not only is the weight relatively large, but also this artificial stone material is relatively rigid and has poor toughness. During use, it will be damaged due to collisions, knocks, etc. during transportation, production, etc., and even crack at a temperature of 70°C (absolute value). Summary of the Invention

[0004] Based on this, some embodiments of the present application provide a lightweight artificial stone material with high impact performance. In addition, some embodiments of the present application also provide a composition of the artificial stone material, a preparation method of the artificial stone material, an artificial stone structural member prepared from the artificial stone material, and a preparation method of the artificial stone structural member.

[0005] In a first aspect, a composition of an artificial stone material is provided, including: a thermoplastic resin, an expanded perlite filler, and a surface modifier;

[0006] Wherein, the particle size of the expanded perlite filler is 3μm to 20μm, and / or, the tapped density of the expanded perlite filler is greater than or equal to 0.48g / cm 3 ;

[0007] The surface modifier is used to modify the surface of the expanded perlite filler, and the oil absorption value of the expanded perlite after being modified by the surface modifier is less than or equal to 150%.

[0008] Optionally,

[0009] The composition satisfies at least one of the following conditions:

[0010] (1) The surface modifier is selected from at least one of silane coupling agents and terminal amino polyol esters; optionally, the silane coupling agent includes at least one of vinyl silane, amino silane, and methacryloxy silane; optionally, the terminal amino polyol ester includes at least one of terminal amino polyether polyol, terminal amino polyolefin polyol, and terminal amino polycarbonate polyol; optionally, the surface modifier includes the silane coupling agent and the terminal amino polyol ester, and the mass ratio of the silane coupling agent to the terminal amino polyol ester is 1:1 to 1:2;

[0011] (2) The density of the expanded perlite filler is 0.17 g / cm 3 ~ 0.20 g / cm 3 and the surface porosity is 60% - 70%;

[0012] (3) The mass ratio of the expanded perlite filler to the surface modifier is 100:0.5 to 100:3;

[0013] (4) The mass ratio of the thermoplastic resin to the expanded perlite filler is 100:60 to 100:150.

[0014] In a second aspect, a method for preparing an artificial stone material is provided, including:

[0015] S11. Provide the composition of the artificial stone material as described in the first aspect;

[0016] S12. Use the surface modifier in the composition of the artificial stone material to perform surface modification on the expanded perlite filler until the oil absorption value of the expanded perlite filler is less than or equal to 150%;

[0017] S13. Mix the surface-modified expanded perlite filler with the thermoplastic resin in the composition of the artificial stone material, and prepare the artificial stone material through melt kneading and cooling.

[0018] Optionally, the surface modifier includes a silane coupling agent and a terminal amino polyol ester, and the mass ratio of the silane coupling agent to the terminal amino polyol ester is 1:1 to 1:2; S12 includes:

[0019] Mix the expanded perlite filler with the silane coupling agent, and prepare the first modified powder through spray drying;

[0020] Mix the first modified powder with the terminal amino polyol ester at 90°C - 110°C for 10 min - 15 min to obtain the second modified powder, thereby performing surface modification on the expanded perlite filler.

[0021] Optionally, S13 includes:

[0022] Under stirring, the thermoplastic resin is heated and melted to obtain a molten liquid;

[0023] The surface-modified expanded perlite filler is added to the molten liquid for internal mixing to obtain a mixed fluid;

[0024] The mixed fluid is shaped and cooled to prepare the artificial stone material.

[0025] Optionally, the preparation method satisfies at least one of the following conditions:

[0026] (1) The temperature of the heating and melting is 240°C to 250°C, and the time is 10 min to 20 min;

[0027] (2) The pressure of the internal mixing is 14 Mpa to 16 Mpa, the rotation speed during the internal mixing is 30 rpm to 35 rpm, and the time is 20 min to 40 min;

[0028] (3) A mold is used to shape and cool the mixed fluid to prepare the artificial stone material.

[0029] Optionally, the artificial stone material is granular; or,

[0030] The artificial stone material is an artificial stone slab;

[0031] Optionally, the artificial stone material satisfies at least one of the following conditions:

[0032] (1) The density of the artificial stone material is 0.9 g / cm 3 ~1.1 g / cm 3 ;

[0033] (2) The flexural strength of the artificial stone material is greater than 80 Mpa;

[0034] (3) The impact resistance height of the artificial stone material is greater than 250 cm.

[0035] In a third aspect, an artificial stone material is provided, including:

[0036] A thermoplastic resin substrate;

[0037] A modified inorganic filler, and the modified inorganic filler is filled in the thermoplastic resin substrate;

[0038] Wherein, the modified inorganic filler includes: an expanded perlite filler and a surface modifier coated on the surface of the expanded perlite filler, the particle size of the expanded perlite filler is 3 μm to 20 μm, and / or, the compacted density of the expanded perlite filler is greater than or equal to 0.48 g / cm 3; The mass ratio of the thermoplastic resin substrate to the expanded perlite filler is 100:60 to 100:150, and the mass ratio of the expanded perlite filler to the surface modifier is 100:0.5 to 100:3.

[0039] Fourthly, a preparation method of an artificial stone structural member is provided. The artificial stone structural member is prepared by molding using the artificial stone material prepared by the preparation method described in the second aspect or the artificial stone material described in the third aspect.

[0040] Optionally, the heating temperature of the molding is 180°C to 200°C, the heat preservation time is 5 min to 10 min, and the applied pressure is 0.15 Mpa to 0.30 Mpa;

[0041] Optionally, the artificial stone structural member satisfies at least one of the following conditions:

[0042] (1) The density of the artificial stone structural member is 0.9 g / cm 3 ~ 1.1 g / cm 3 , optionally 0.96 g / cm 3 ~ 1.05 g / cm 3 ;

[0043] (2) The flexural strength of the artificial stone structural member is greater than 80 Mpa, optionally greater than or equal to 98 Mpa;

[0044] (3) The impact resistance height of the artificial stone structural member is greater than 250 cm.

[0045] The beneficial effects of the above artificial stone material composition, artificial stone material, artificial stone structural member and its preparation method are as follows:

[0046] By controlling the particle size of the expanded perlite filler to be 3 μm to 20 μm, and / or the tapped density of the expanded perlite filler is greater than or equal to 0.48 g / cm 3 , the oil absorption value of the expanded perlite filler can be adjusted, so as to facilitate the mixing of the expanded perlite filler and the thermoplastic resin in a certain mass ratio and processing into an artificial stone material; at the same time, in order to improve the compatibility between the expanded perlite filler and the thermoplastic resin, a surface modifier is added to the composition, and the addition of the surface modifier can further adjust the oil absorption value of the expanded perlite. For example, by controlling the oil absorption value of the expanded perlite filler modified by the surface modifier to be less than or equal to 150%, a lightweight and high-impact performance artificial stone material can be prepared. Description of the Drawings

[0047] Figure 1 It is a schematic flow chart of a preparation method of an artificial stone material provided by an embodiment of the present application. Detailed Implementation Modes

[0048] To make the above objects, features, and advantages of the present application more apparent and understandable, the following provides a detailed description of the specific implementation modes of the present application in conjunction with the accompanying drawings. Many specific details are set forth in the following description to facilitate a full understanding of the present application. However, the present application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar improvements without departing from the connotation of the present application. Therefore, the present application is not limited by the specific embodiments disclosed below.

[0049] Unless the context otherwise requires, throughout the specification and claims, the term "comprising" is to be construed in an open, inclusive sense, i.e., "including, but not limited to". In the description of the specification, the terms "one embodiment", "some embodiments", "exemplary embodiments", "exemplarily", or "some examples", etc., are intended to indicate that specific features, structures, materials, or characteristics related to the embodiment or example are included in at least one embodiment or example of the present disclosure. The schematic representations of the above terms are not necessarily directed to the same embodiment or example. In addition, the specific features, structures, materials, or characteristics described above may be included in any one or more embodiments or examples in any appropriate manner.

[0050] In this document, exemplary implementation modes are described with reference to cross-sectional views and / or plan views as idealized exemplary drawings. In the drawings, the thickness of layers and regions is exaggerated for clarity. Therefore, variations in the shape relative to the drawings due to, for example, manufacturing techniques and / or tolerances can be envisioned. Therefore, the exemplary implementation modes should not be construed as limited to the shapes of the regions shown herein, but include shape deviations caused by, for example, manufacturing. For example, an etched region shown as rectangular will generally have curved features. Therefore, the regions shown in the drawings are schematic in nature, and their shapes are not intended to show the actual shape of the regions of the device and are not intended to limit the scope of the exemplary implementation modes.

[0051] In this document, terms such as "for example", "such as", "example", "for illustration", etc., are used for descriptive purposes, indicating an association in terms of the covered content between the different technical solutions before and after, but should not be construed as a limitation on the previous technical solution, nor as a limitation on the scope of protection of this document. In this document, unless otherwise stated, A (such as B) means that B is a non-limiting example of A, and it can be understood that A is not limited to B.

[0052] In this document, "optionally", "optional", "option", mean that it can be either present or absent, that is, it refers to any one of the two parallel options of "present" or "absent". If "optional" appears multiple times in a technical solution, unless otherwise specified and there are no contradictions or mutual restrictions, each "optional" is independent.

[0053] In this text, descriptions such as "optionally containing" and "optionally including" mean "containing or not containing". "Optional component X" means that component X is present or absent, or means containing or not containing this component X.

[0054] In "the first aspect", "the second aspect", etc. in this text, the terms "first", "second", etc. are only for descriptive purposes and cannot be understood as indicating or implying relative importance or quantity, nor can they be understood as implicitly indicating the importance or quantity of the indicated technical features.

[0055] It should be noted that when an element is referred to as "fixed to" or "disposed on" another element, it can be directly on the other element or there may also be an intermediate element. When an element is considered to be "connected" to another element, it can be directly connected to the other element or there may be an intermediate element at the same time. The terms "vertical", "horizontal", "upper", "lower", "left", "right" and similar expressions used in this text are only for illustrative purposes and do not represent the only implementation.

[0056] Unless otherwise defined, all technical and scientific terms used in this text have the same meaning as those commonly understood by those skilled in the technical field to which this application belongs. The terms used in the specification of this application in this text are only for the purpose of describing specific embodiments and are not intended to limit this application.

[0057] In this text, among the technical features described in an open-ended manner, it includes a closed technical solution composed of the listed features, and also includes an open technical solution containing the listed features.

[0058] In this text, the meaning of "at least one" is more than one, such as one, two or more. The meaning of "multiple" or "several" is at least two, such as two, three, etc.

[0059] In this text, regarding a numerical interval (i.e., a numerical range), unless otherwise specified, the distribution of the optional numerical values within this numerical interval is considered continuous and includes the two numerical endpoints (i.e., the minimum value and the maximum value) of this numerical interval, as well as each numerical value between these two numerical endpoints. Unless otherwise specified, when the numerical interval only refers to the integers within this numerical interval, it includes the two endpoint integers of this numerical range, as well as each integer between the two endpoints, which is equivalent to directly listing each integer. When providing multiple numerical ranges to describe features or characteristics, these numerical ranges can be combined. In other words, unless otherwise specified, the numerical ranges disclosed in this text should be understood as including any and all sub-ranges subsumed therein. The "numerical value" in this numerical interval can be any quantitative value, such as a number, a percentage, a ratio, etc. The "numerical interval" allows for a broad inclusion of numerical interval types such as percentage intervals, ratio intervals, ratio value intervals, etc.

[0060] In this text, when it comes to percentage concentration, unless otherwise specified, it refers to the final concentration. The so-called final concentration refers to the proportion of the added component in the system after adding this component.

[0061] In this text, when a method process involves multiple steps, unless there are clear different descriptions in this text, the execution of these steps has no strict order limit, and they can be executed in an order other than the described one. Moreover, any step may include multiple sub-steps or multiple stages. These sub-steps or stages do not necessarily need to be completed at the same moment, but can be executed at different moments, and their execution order does not necessarily need to be sequential, but can be executed alternately or simultaneously with other steps or a part of the sub-steps or stages of other steps.

[0062] Aiming at the technical problems in the related art that artificial stone materials are heavy in weight and prone to cracking, etc., the specific implementation manners of this application are described as follows:

[0063] In a first aspect, some embodiments of this application provide a composition of an artificial stone material, and this composition includes: a thermoplastic resin, an expanded perlite filler, and a surface modifier; wherein, the particle size of this expanded perlite filler is 3 μm to 20 μm, and / or, the tapped density of this expanded perlite filler is greater than or equal to 0.48 g / cm 3 ; this surface modifier is used to modify the surface of the expanded perlite filler, and the oil absorption value of the expanded perlite after being modified by the surface modifier is less than or equal to 150%.

[0064] Among them, perlite is a vitreous rock formed by the rapid cooling of acidic lava erupted from a volcano.

[0065] The density of unexpanded perlite is relatively high. As the name implies, the expanded perlite filler refers to perlite after being processed by expansion, and its density is relatively low.

[0066] The surface of unexpanded perlite has a small number of micropores. When undergoing expansion processing, the water inside the perlite evaporates, and the generated steam pressure causes the perlite to expand into a porous structure. Therefore, the surface of the expanded perlite filler has a large number of microporous structures.

[0067] During the preparation of artificial stone, the expanded perlite filler with a relatively large particle size has a very large oil absorption value and requires a large amount of thermoplastic resin for processing, which is difficult to apply. Therefore, in this application, this expanded perlite can be obtained by crushing and expanding perlite, which can reduce the particle size of the expanded perlite and facilitate subsequent application.

[0068] The oil absorption value, also known as the oil absorption capacity, refers to the minimum amount of oil required for a certain mass of powdery material (such as expanded perlite filler) to reach complete wetting. Here, at least one of unsaturated polyester, epoxy resin, or acrylic resin can be used as the oil for measuring the oil absorption value of the expanded perlite filler.

[0069] The tapped density refers to the mass per unit volume when powder or granular material is filled into a container under certain conditions and reaches the most tightly packed state after mechanical vibration, which is used to measure the packing tightness of powder or granular material in practical applications and is related to the shape, size distribution, and surface properties such as surface roughness of the powder or granules.

[0070] In this application, the tapped density of the expanded perlite filler can be measured using the tapped density meter ZS - 201 from Changzhou Dedoo Precision Instruments Co., Ltd. The test conditions are: vibration frequency of 200 r / min, vibration amplitude of 3 mm, and vibration times of 3000 times.

[0071] In the composition of the artificial stone material provided in the embodiments of this application, by controlling the particle size of the expanded perlite filler to be 3 μm to 20 μm, and / or the tapped density of the expanded perlite filler is greater than or equal to 0.48 g / cm 3 ³, the oil absorption value of the expanded perlite filler can be adjusted, so as to facilitate the mixing of the expanded perlite filler and the thermoplastic resin in a certain mass ratio and processing into artificial stone materials; at the same time, in order to improve the compatibility between the expanded perlite filler and the thermoplastic resin, a surface modifier is added to the composition, and the addition of the surface modifier can further adjust the oil absorption value of the expanded perlite. For example, by controlling the oil absorption value of the expanded perlite filler modified by the surface modifier to be less than or equal to 150%, a lightweight and high - impact performance artificial stone material can be prepared.

[0072] Among them, no specific limitations are imposed on the density, surface porosity, etc. of the above - mentioned expanded perlite filler, and all expanded perlite fillers that meet the above - mentioned mesh number and / or tapped density are within the protection scope of this application.

[0073] In some embodiments, the density of the expanded perlite filler is 0.17 g / cm 3 ~0.20 g / cm 3 ³, and the surface porosity is 60% - 70%.

[0074] In these embodiments, by controlling the density of the expanded perlite filler to be 0.17 g / cm 3 ~0.20 g / cm 3, with a surface porosity of 60% - 70%, can reduce the oil absorption value as much as possible, thereby facilitating the compatibility of the thermoplastic resin and expanded perlite to prepare an artificial stone material with excellent hydrogen production and impact resistance.

[0075] In some embodiments, the surface modifier is selected from at least one of silane coupling agents and terminal amino polyol esters.

[0076] Both silane coupling agents and terminal amino polyol esters can modify the surface of the expanded perlite filler, thereby improving the compatibility between the expanded perlite filler and the thermoplastic resin.

[0077] In some embodiments, the silane coupling agent includes at least one of vinyl silane, amino silane, and methacryloxy silane; the terminal amino polyol ester includes at least one of terminal amino polyether polyol ester, terminal amino polyolefin polyol ester, and terminal amino polycarbonate polyol ester.

[0078] In some embodiments, the surface modifier includes a silane coupling agent and a terminal amino polyol ester, and the mass ratio of the silane coupling agent to the terminal amino polyol ester is 1:1 - 1:2.

[0079] In these embodiments, by controlling the mass ratio of the silane coupling agent to the terminal amino polyol ester to be 1:1 - 1:2, the compatibility between the expanded perlite filler and the thermoplastic resin can be more effectively improved.

[0080] In some embodiments, the mass ratio of the expanded perlite filler to the surface modifier is 100:0.5 - 100:3.

[0081] In these embodiments, by controlling the mass ratio of the expanded perlite filler to the surface modifier to be 100:0.5 - 100:3, it is convenient to modify the surface of the expanded perlite filler, improve the compatibility between the surface-modified expanded perlite filler and the thermoplastic resin, and improve the processing performance.

[0082] In some embodiments, the mass ratio of the thermoplastic resin to the expanded perlite filler is 100:60 - 100:150.

[0083] In these embodiments, by controlling the oil absorption amount, the mass ratio of the thermoplastic resin to the expanded perlite filler can be controlled to be 100:60 - 100:150, which is convenient for processing and preparing artificial stone materials with different performance requirements (such as different densities, different flexural strengths, and different impact strengths).

[0084] Second, some embodiments of the present application provide a method for preparing an artificial stone material, as Figure 1 shown, including the following steps S11 - S13:

[0085] S11. Provide the composition of the artificial stone material as described in the first aspect;

[0086] The composition of the artificial stone material includes: a thermoplastic resin, an expanded perlite filler, and a surface modifier; wherein, the particle size of the expanded perlite filler is 3 μm to 20 μm, and / or, the tapped density of the expanded perlite filler is greater than or equal to 0.48 g / cm 3 ; The surface modifier is used to modify the surface of the expanded perlite filler.

[0087] S12. Use the surface modifier in the composition of the artificial stone material to modify the surface of the expanded perlite filler until the oil absorption value of the expanded perlite filler is less than or equal to 150%;

[0088] S13. Mix the surface-modified expanded perlite filler with the thermoplastic resin in the composition of the artificial stone material, and prepare the artificial stone material through melt kneading and cooling.

[0089] In the preparation method of the artificial stone material provided in the embodiments of the present application, by using the surface modifier in the composition of the artificial stone material described in the first aspect to modify the surface of the expanded perlite filler until the oil absorption value of the expanded perlite filler is less than or equal to 150%, and then mixing the surface-modified expanded perlite filler with the thermoplastic resin in the composition of the artificial stone material in a certain proportion (this proportion corresponds to the oil absorption value), and through melt kneading and cooling, the artificial stone material can be prepared. The preparation method is simple and easy to implement.

[0090] In some embodiments, the expanded perlite filler in S11) can be obtained by crushing and expanding perlite. Compared with before expansion, the expanded perlite has a richer pore structure, a smaller density, and stronger water absorption, heat insulation, and fire resistance on the surface.

[0091] Exemplarily, in some embodiments, before crushing and expansion, the mesh number of perlite can be 40 mesh to 120 mesh. After crushing and expansion, the particle size of the expanded perlite filler is 3 μm to 20 μm.

[0092] In some embodiments, the density of the expanded perlite can be 0.17 g / cm 3 ~0.20 g / cm 3 , and the surface porosity can be 60% to 70%.

[0093] In some embodiments, the above surface modifier includes: a silane coupling agent and an amino-terminated polyol ester, and the mass ratio of the silane coupling agent to the amino-terminated polyol ester is 1:1 to 1:2; S12 includes:

[0094] Mix the expanded perlite filler with the silane coupling agent, and prepare the first modified powder through spray drying;

[0095] Mix the first modified powder with the amino - terminated polyol ester at 90 °C to 110 °C for 10 min to 15 min to obtain the second modified powder, thereby surface - modifying the expanded perlite filler.

[0096] In these embodiments, first, use a silane coupling agent to modify the expanded perlite filler to obtain the first modified powder, and then use the amino - terminated polyol ester to further modify the first modified powder to obtain the second modified powder, so as to surface - modify the expanded perlite filler. The modified expanded perlite filler thus obtained has better compatibility with the thermoplastic resin.

[0097] In some embodiments, S13 includes:

[0098] S131. Under stirring, heat - melt the thermoplastic resin to obtain a molten liquid;

[0099] S132. Add the surface - modified expanded perlite filler to the molten liquid and conduct internal mixing to obtain a mixed fluid;

[0100] S133. Shape and cool the mixed fluid to prepare artificial stone materials.

[0101] In these embodiments, by heating - melting the thermoplastic resin under stirring to obtain a molten liquid, and then adding the surface - modified expanded perlite filler to the molten liquid for internal mixing, the surface - modified expanded perlite filler can be fully melted into the thermoplastic resin, and the mixing is more uniform. Finally, by shaping and cooling the mixed fluid, artificial stone materials can be prepared.

[0102] In some embodiments, in S131, the temperature of the above - mentioned heat - melting is 240 °C to 250 °C, and the time is 10 min to 20 min.

[0103] Exemplarily, stirring can be carried out in an internal mixer to heat - melt the thermoplastic resin.

[0104] In some embodiments, in S132, the pressure of the above - mentioned internal mixing is 14 Mpa to 16 Mpa, the rotation speed during internal mixing is 30 rpm to 35 rpm, and the time is 20 min to 40 min.

[0105] In these embodiments, by controlling the pressure, stirring speed and time of internal mixing, the surface - modified expanded perlite filler and the thermoplastic resin can be fully mixed, so that artificial stone materials with uniform texture can be prepared.

[0106] In some embodiments, in S133, a mold can be used to shape and cool the mixed fluid to prepare artificial stone materials.

[0107] In these embodiments, the artificial stone material can be prepared into any possible shape by injection molding.

[0108] In some embodiments, the artificial stone material can be granular. In this case, the artificial stone material can be used as a raw material for preparing artificial stone structural components, and the prepared artificial stone structural components have the characteristics of light weight, excellent impact resistance and bending performance.

[0109] In other embodiments, the artificial stone material can be an artificial stone slab. In this case, the artificial stone slab itself has the characteristics of light weight, excellent impact resistance and bending performance, and can be applied to various scenarios with high requirements for material weight and toughness.

[0110] In some embodiments, the artificial stone material satisfies at least one of the following conditions:

[0111] (1) The density of the artificial stone material is 0.9 g / cm 3 ~1.1g / cm 3 ;

[0112] (2) The bending strength of the artificial stone material is greater than 80 Mpa;

[0113] (3) The impact resistance height of the artificial stone material is greater than 250 cm.

[0114] In these embodiments, the artificial stone material has the characteristics of light weight, excellent impact resistance and bending performance, and can meet the requirements of various scenarios when applied to the fields of architecture, decoration, etc.

[0115] In a third aspect, some embodiments of the present application provide an artificial stone material, including:

[0116] A thermoplastic resin substrate;

[0117] A modified inorganic filler, and the modified inorganic filler is filled in the thermoplastic resin substrate;

[0118] Wherein, the modified inorganic filler includes: expanded perlite filler and a surface modifier coated on the surface of the expanded perlite filler, the particle size of the expanded perlite filler is 3 μm to 20 μm, and / or, the compacted density of the expanded perlite filler is greater than or equal to 0.48 g / cm 3 ; The mass ratio of the thermoplastic resin substrate to the expanded perlite filler is 100:60 to 100:150, and the mass ratio of the expanded perlite filler to the surface modifier is 100:0.5 to 100:3.

[0119] Fourthly, some embodiments of the present application provide a method for preparing an artificial stone structural member. The artificial stone structural member is prepared by molding the artificial stone material prepared by the preparation method of the second aspect or the artificial stone material described in the third aspect.

[0120] The artificial stone structural member can be of any possible shape to meet the application requirements.

[0121] Molding means putting the artificial stone material into a mold, heating the mold to soften the artificial stone material, and under the pressure applied by a press, making the artificial stone material flow in the mold and fill the entire cavity and then cooling, so as to obtain an artificial stone structural member with a certain shape.

[0122] In some embodiments, the heating temperature of the above molding is 180°C to 200°C, the heat preservation time is 5 min to 10 min, and the applied pressure is 0.15 Mpa to 0.30 MPa.

[0123] In these embodiments, by controlling the heating temperature, heat preservation time and applied pressure of the molding, the mechanical properties of the artificial stone structural member can be controlled, so as to obtain an artificial stone structural member that can meet the application requirements.

[0124] In some embodiments, the artificial stone structural member satisfies at least one of the following conditions:

[0125] (1) The density of the artificial stone structural member is 0.9 g / cm 3 ~1.1 g / cm 3 , optionally 0.96 g / cm 3 ~1.05 g / cm 3 ;

[0126] (2) The flexural strength of the artificial stone structural member is greater than 80 Mpa, optionally greater than or equal to 98 Mpa;

[0127] (3) The impact resistance height of the artificial stone structural member is greater than 250 cm.

[0128] In these embodiments, the artificial stone structural member has excellent flexural strength and impact resistance performance, and can be applied to a variety of scenarios with relatively light weight requirements, so as to meet a variety of use requirements.

[0129] In order to objectively evaluate the technical effects of the embodiments of the present application, the present application will be described in detail and exemplarily through the following examples and comparative examples.

[0130] In the following examples and comparative examples, all raw materials can be obtained commercially. To ensure the reliability of the experiments, the raw materials used in the following examples and comparative examples have the same physical and chemical parameters or are prepared by the same treatment methods.

[0131] Among them, in the following examples and comparative examples, the material parameters used are as follows:

[0132] Perlite: industrial grade, purchased from Shijiazhuang Hualang Mining Trade Co., Ltd., with a mesh size of 50 mesh.

[0133] Silane coupling agent: amino silane coupling agent, purchased from Hangzhou Jessica Chemical Co., Ltd., model KH-550.

[0134] Modifier: terminal amino polyol ester, purchased from Nanjing Jinlaiwang New Material Technology Co., Ltd., model JL-G02FX.

[0135] PMMA (acrylic): purchased from LG Chem, grade PMMA IF850.

[0136] Pigment and filler: titanium dioxide, purchased from Titanium Industry Co., Ltd. of Pangang Group, model R-258.

[0137] Oil for oil absorption value measurement: unsaturated polyester, purchased from Xinyang Technology Group Co., Ltd., model DC191.

[0138] The oil absorption values of the expanded perlite filler after crushing and surface modification treatment and the expanded perlite filler without crushing and surface modification treatment were measured. The measurement results and the corresponding relationships between the tapped density after crushing and the addition ratio of the surface modifier are shown in Table 1 below.

[0139] Table 1

[0140]

[0141] Among them, the measurement method of the oil absorption value of each of the above-mentioned schemes is as follows:

[0142] 1. Accurately weigh the weight of the sample to be measured, wrap it with gauze and put it into a beaker, and weigh the total weight.

[0143] 2. Add a certain amount of oil solution to the beaker, and fully immerse the expanded perlite filler treated according to the scheme shown in Table 1 for each scheme, ensuring that the liquid to be measured is in full contact with the surface of the filler.

[0144] 3. After a certain period of liquid absorption, take out the soaked expanded perlite filler, untie the gauze, and put the gauze back into the beaker.

[0145] 4. Weigh the beaker and gauze again, calculate the difference in mass of the adsorbed grease liquid, and you can get the oil absorption of the expanded perlite filler. The calculation formula is: Oil absorption value (weight %) = (resin used (g) / sample weight (g)) × 100.

[0146] The expanded perlite filler, PMMA and surface modifier are set as embodiments according to the proportion relationship and treatment method of Scheme 5, and the traditional technology is set as a comparative example to prepare artificial stone structural parts, and the performance parameters of the artificial stone structural parts prepared in each embodiment and comparative example are tested to illustrate the beneficial technical effects of the present application.

[0147] Example 1

[0148] Embodiment 1 provides an artificial stone structure, and its preparation method is as follows:

[0149] Step 1), add the pearlite particles into a vibrating mill for crushing to obtain a high tap density of 0.48g / cm 3 Perlite powder sample A;

[0150] Step 2), the powder sample A obtained in step 1) is mixed with the KH550 solution at a mass ratio of the powder sample A to the KH550 of 100:1, and the powder sample B is obtained by spray drying;

[0151] Step 3), add powder sample B into a high-speed mixer, and then add JL-G02FX according to the weight ratio, the mass ratio of powder sample A to JL-G02FX is 100:1, and mix at high speed at 100°C for 12 minutes to obtain modified powder sample C;

[0152] Step 4) Add PMMA into an internal mixer and plasticize at 245°C for 15 minutes, then add a certain proportion of powder sample C and pigments and fillers, the mass ratio of PMMA to powder sample C is 100:60, set the internal mixer pressure to 15 MPa, and the speed to 32 rpm; knead for 30 minutes to obtain a uniformly mixed molten fluid mixture;

[0153] Step 5), pour the molten fluid mixture into a silicone mold to cool and shape it, and then obtain an artificial stone material with an artificial stone texture, light weight and toughness;

[0154] Step 6), placing the artificial stone material prepared above in a molding device, heating it to 190°C and keeping it warm for 8 minutes, and after the material softens, applying a pressure of 0.20 MPa, and then preparing an artificial stone structural panel according to the selected mold.

[0155] Example 2

[0156] The preparation method of the artificial stone structural member provided in Example 2 is basically the same as that of the artificial stone structural member provided in Example 1, except that:

[0157] In step 4), the mass ratio of PMMA to powder sample C is 100:90.

[0158] Example 3

[0159] The preparation method of the artificial stone structural member provided in Example 3 is basically the same as that of the artificial stone structural member provided in Example 1, except that:

[0160] In step 4), the mass ratio of PMMA to powder sample C is 100:120.

[0161] Example 4

[0162] The preparation method of the artificial stone structural member provided in Example 4 is basically the same as that of the artificial stone structural member provided in Example 1, except that:

[0163] In step 4), the mass ratio of PMMA to powder sample C is 100:150.

[0164] Comparative Example 1

[0165] The preparation method of the artificial stone structural member provided in Comparative Example 1 is as follows:

[0166] Mix 70wt% quartz sand and 30wt% unsaturated polyester, add methyl ethyl ketone peroxide as a curing agent and stir evenly, then pour it into a mold for curing and molding. Among them, the product model of the unsaturated polyester is C7A, the product model of the curing agent is Akzo M50, and the addition amount of the curing agent is 1wt% of the unsaturated polyester.

[0167] Test Example

[0168] 1. Measure the density, flexural strength and impact strength of the artificial stone structural plates provided in Examples 1 to 5 and Comparative Example 1:

[0169] Among them, the flexural strength is measured with reference to Section 7.8.1 of the JC / T 908-2013 artificial stone standard, and the corresponding relationship between the measurement results and the addition ratios of the components in each example and comparative example is shown in Table 2 below.

[0170] The measurement method of the impact strength is as follows:

[0171] Fix the artificial stone structural plate with a length * width of 130mm * 130mm, and let a 450mm steel ball freely fall from a certain height to the center of the artificial stone structural plate, and measure the maximum impact height without damage. The corresponding relationship between the measurement results and the addition ratios of the components in each example and comparative example is shown in Table 2 below.

[0172] Table 2

[0173]

[0174] As can be seen from Table 2, the artificial stone structural panel provided in Comparative Example 1 is heavy in weight and poor in impact resistance, while in Examples 1 to 4, artificial stone structural panels with light weight and excellent mechanical properties can be obtained. Specifically, as the proportion of expanded perlite filler increases, the density and flexural strength of the artificial stone structural panel gradually decrease, while the impact resistance shows that no damage occurs when the impact height > 250 cm.

[0175] The technical features of the above-described embodiments can be combined arbitrarily. For the sake of brevity of description, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, it should be considered as the scope described in this specification.

[0176] The above-described embodiments only represent several implementation manners of the present application, and the description thereof is relatively specific and detailed, but it should not be construed as a limitation on the scope of the patent application. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present application, several modifications and improvements can still be made, and these all belong to the protection scope of the present application. Therefore, the protection scope of the patent of the present application shall be subject to the appended claims.

Claims

1. A composition of artificial stone material, characterized in that: include: Thermoplastic resin, expanded perlite filler and surface modifier; The particle size of the expanded perlite filler is 3 μm to 20 μm, and / or the tap density of the expanded perlite filler is greater than or equal to 0.48 g / cm 3 ; The surface modifier is used to modify the surface of the expanded perlite filler, and the oil absorption value of the expanded perlite filler after being modified by the surface modifier is less than or equal to 150%.

2. The composition of artificial stone material according to claim 1, characterized in that: The composition satisfies at least one of the following conditions: (1) The surface modifier is selected from at least one of a silane coupling agent and an amino-terminated polyol ester; optionally, the silane coupling agent includes: at least one of vinyl silane, aminosilane, and methacryloxysilane; optionally, the amino-terminated polyol ester includes: at least one of amino-terminated polyether polyol ester, amino-terminated polyolefin polyol ester, and amino-terminated polycarbonate polyol ester; optionally, the surface modifier includes: the silane coupling agent and the amino-terminated polyol ester, and the mass ratio of the silane coupling agent to the amino-terminated polyol ester is 1:1 to 1:2; (2) The density of the expanded perlite filler is 0.17 g / cm 3 ~0.20 g / cm 3 , the surface porosity is 60%~70%; (3) The mass ratio of the expanded perlite filler to the surface modifier is 100:0.5 to 100:3; (4) The mass ratio of the thermoplastic resin to the expanded perlite filler is 100:60 to 100:

150.

3. A method for preparing an artificial stone material, characterized in that: include: S11, providing a composition of the artificial stone material according to any one of claims 1 to 2; S12, using the surface modifier in the composition of the artificial stone material to perform surface modification on the expanded perlite filler, until the oil absorption value of the expanded perlite filler is less than or equal to 150%; S13, mixing the surface-modified expanded perlite filler with the thermoplastic resin in the composition of the artificial stone material, and preparing the artificial stone material through melt-kneading and cooling.

4. The method for preparing the artificial stone material according to claim 3, characterized in that: The surface modifier comprises: a silane coupling agent and an amino-terminated polyol ester, wherein the mass ratio of the silane coupling agent to the amino-terminated polyol ester is 1:1 to 1:2; S12 comprises: The expanded pearlite filler is mixed with the silane coupling agent, and a first modified powder is prepared by spray drying; The first modified powder is mixed with the amino-terminated polyol ester at 90° C. to 110° C. for 10 min to 15 min to obtain a second modified powder, thereby performing surface modification on the expanded pearlite filler.

5. The method for preparing the artificial stone material according to claim 3, characterized in that: S13, including: Under stirring, heating and melting the thermoplastic resin to obtain a molten liquid; adding the surface-modified expanded pearlite filler into the molten liquid for internal kneading to obtain a mixed fluid; The mixed fluid is shaped and cooled to prepare the artificial stone material.

6. The method for preparing the artificial stone material according to claim 5, characterized in that: The preparation method satisfies at least one of the following conditions: (1) The heating and melting temperature is 240°C to 250°C, and the time is 10 min to 20 min; (2) The pressure of the banburying is 14 MPa to 16 MPa, the speed of the banburying is 30 rpm to 35 rpm, and the time is 20 min to 40 min; (3) Using a mold to shape and cool the mixed fluid to prepare the artificial stone material.

7. The method for preparing an artificial stone material according to any one of claims 3 to 6, characterized in that: The artificial stone material is granular; or, The artificial stone material is an artificial stone slab; Optionally, the artificial stone material satisfies at least one of the following conditions: (1) The density of the artificial stone material is 0.9 g / cm 3 ~1.1g / cm 3 ; (2) The bending strength of the artificial stone material is greater than 80Mpa; (3) The impact resistance height of the artificial stone material is greater than 250 cm.

8. An artificial stone material, characterized in that: include: Thermoplastic resin substrate; A modified inorganic filler, wherein the modified inorganic filler is filled in the thermoplastic resin substrate; The modified inorganic filler comprises: an expanded perlite filler and a surface modifier coated on the surface of the expanded perlite filler, the particle size of the expanded perlite filler is 3 μm to 20 μm, and / or the compacted density of the expanded perlite filler is greater than or equal to 0.48 g / cm 3 ; The mass ratio of the thermoplastic resin substrate to the expanded perlite filler is 100:60~100:150, and the mass ratio of the expanded perlite filler to the surface modifier is 100:0.5~100:

3.

9. A method for preparing an artificial stone structural member, characterized in that: The artificial stone structural component is prepared by molding the artificial stone material prepared by the preparation method according to any one of claims 3 to 7 or the artificial stone material according to claim 8.

10. The method for preparing an artificial stone structural member according to claim 9, characterized in that: The heating temperature of the molding is 180°C to 200°C, the holding time is 5 min to 10 min, and the applied pressure is 0.15 Mpa to 0.30 Mpa; Optionally, the artificial stone structure meets at least one of the following conditions: (1) The density of the artificial stone structure is 0.9 g / cm 3 ~1.1 g / cm 3 , optionally 0.96 g / cm 3 ~1.05 g / cm 3 ; (2) The bending strength of the artificial stone structure is greater than 80 MPa, and optionally greater than or equal to 98 MPa; (3) The impact resistance height of the artificial stone structure is greater than 250 cm.

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