Artificial stone with high mechanical property and preparation method thereof

Abstract

The invention relates to the technical field of artificial stones, in particular to an artificial stone with high mechanical property and a preparation method of the artificial stone. The artificial stone slurry is prepared from the following components in parts by mass: 3 to 60 parts of extra-coarse aggregate, 2 to 40 parts of common coarse aggregate, 17 to 65 parts of calcium sand, 12 to 30 parts of cement, 0.5 to 6 parts of active mineral admixture, 0.01 to 2 parts of suspension stabilizer, 0.3 to 2.5 parts of water reducing agent, 0.1 to 2 parts of fiber and 4.0 to 7.5 parts of water, the particle size of the extra-coarse aggregate is 12-100 cm; and the particle size of the common coarse aggregate is 0.1-10 cm. According to the artificial stone with the high mechanical property, the extra-coarse aggregate is applied to the artificial stone, the mechanical property and the appearance of the artificial stone are improved on the premise that the sedimentation problem of the extra-coarse aggregate is effectively solved and stable application of the extra-coarse aggregate in the artificial stone is ensured, and the defects in the prior art are overcome.

Description

Technical Field

[0001] The present invention relates to the technical field of artificial stone, and particularly relates to an artificial stone with high mechanical properties and a preparation method thereof. Background Art

[0002] Artificial stone is a decorative material formed by curing a slurry of artificial stone composed of raw materials such as quartz sand and calcium carbonate. It not only has the beautiful texture of natural stone but also has excellent properties such as wear resistance, high temperature resistance, and corrosion resistance, and is widely used in many fields such as home decoration, commercial places, and medical facilities.

[0003] In the preparation process of artificial stone, the selection of aggregate plays a crucial role. For a long time, fine aggregate has dominated the production process of artificial stone due to its excellent mixing uniformity, good forming effect, and delicate surface texture. However, with the increasingly diverse market demands, consumers have put forward more stringent requirements for the decorative effect of artificial stone. Compared with fine aggregate, coarse aggregate can create a distinct contrast effect visually with its larger particle size, significantly enhancing the dimensional sense and morphological expressiveness of decoration, and thus can create a rough, vivid, rich-layered, and prominent decorative surface pattern, making the artificial stone prepared with coarse aggregate gradually stand out in the market and be highly favored.

[0004] However, coarse aggregate faces many challenges in the process of being used to prepare artificial stone. Among them, the most prominent problem is the sedimentation problem of coarse aggregate. Due to the large volume and weight of coarse aggregate, its sedimentation speed under the action of gravity is much faster than that of fine aggregate, resulting in its easy aggregation during the preparation process and difficult to achieve uniform distribution in the artificial stone slurry, leading to voids or holes in the prepared artificial stone, which not only affects its appearance but also weakens its mechanical properties.

[0005] Since the performance of artificial stone mainly depends on the artificial stone slurry, in order to overcome the above defects, the prior art has improved the raw materials of the artificial stone slurry in an attempt to solve the sedimentation problem of coarse aggregate. However, due to the differences in the selection of its raw materials and the preparation process, it can only solve the sedimentation problem of ordinary coarse aggregate (i.e., coarse aggregate with a particle size within 10 cm), and the application of coarse aggregate with a particle size ≥ 10 cm (i.e., extra-coarse aggregate) is still a technical problem to be solved urgently. In addition, even when using ordinary coarse aggregate, due to the influence of factors such as raw materials and preparation process, the appearance and mechanical properties of the prepared artificial stone are limited and difficult to meet the actual application requirements.

[0006] Therefore, how to solve the sedimentation problem of extra-coarse aggregate and ensure its stable application in artificial stone, while improving the appearance and mechanical properties of artificial stone, has become a technical problem to be solved urgently. Summary of the Invention

[0007] The object of the present invention is to provide an artificial stone with high mechanical properties. By applying extra-coarse aggregates to the artificial stone, while effectively solving the sedimentation problem of the extra-coarse aggregates and ensuring their stable application in the artificial stone, the mechanical properties and appearance of the artificial stone are improved to overcome the deficiencies in the prior art.

[0008] Another object of the present invention is to provide a preparation method for an artificial stone with high mechanical properties. The preparation method is simple and highly operable, ensuring that the obtained artificial stone has a flexural strength ≥50 MPa, a compressive strength ≥170 MPa, and an impact resistance ≥4 kJ / m 2 , and not only has high mechanical properties but also has a good appearance.

[0009] To achieve this purpose, the present invention adopts the following technical solutions:

[0010] An artificial stone with high mechanical properties, obtained by curing and hardening an artificial stone slurry;

[0011] Calculated by mass parts, the artificial stone slurry includes 3 - 60 parts of extra-coarse aggregates, 2 - 40 parts of ordinary coarse aggregates, 17 - 65 parts of calcium sand, 12 - 30 parts of cement, 0.5 - 6 parts of active mineral admixtures, 0.01 - 2 parts of suspension stabilizers, 0.3 - 2.5 parts of water reducers, 0.1 - 2 parts of fibers, and 4.0 - 7.5 parts of water;

[0012] The particle size of the extra-coarse aggregates is 12 - 100 cm; the particle size of the ordinary coarse aggregates is 0.1 - 10 cm.

[0013] Further, the length of the fibers is 6 - 12 cm, and the diameter is 60 - 120 mm;

[0014] The fibers include any one or a combination of steel fibers, basalt fibers, polyethylene fibers, polyoxymethylene fibers, and chopped carbon fibers.

[0015] Further, the active mineral admixtures include any one or a combination of fly ash, silica fume, metakaolin, slag powder, and steel slag powder;

[0016] The chemical compositions of the slag powder and the steel slag powder both include silicon dioxide and aluminum oxide.

[0017] Further, the suspension stabilizers include any one or a combination of barium-zinc stabilizers, calcium-zinc stabilizers, rare earth calcium-zinc stabilizers, polyurea formaldehyde, polyamide, hydroxyethyl methyl cellulose, hydroxyethyl cellulose, and polyvinyl alcohol.

[0018] Furthermore, the raw materials of the artificial stone slurry further include a modifier, and the modifier includes any one or a combination of more than one of sulfonated naphthalene formaldehyde, nano-silica sol, nano-silica dioxide, nano-aluminum trioxide, and silane coupling agent;

[0019] Calculated by mass parts, the artificial stone slurry includes 3 - 60 parts of extra-coarse aggregate, 2 - 40 parts of ordinary coarse aggregate, 17 - 65 parts of calcium sand, 12 - 30 parts of cement, 0.5 - 6 parts of active mineral admixture, 0.001 - 2 parts of suspension stabilizer, 0.03 - 2.5 parts of water reducing agent, 0.05 - 3.5 parts of modifier, 0.001 - 2 parts of fiber, and 4.0 - 7.5 parts of water.

[0020] Furthermore, calculated by mass parts, the calcium sand includes 5 - 20 parts of a first type of sand material with a mesh size of 70 - 80, 8 - 25 parts of a second type of sand material with a mesh size of 90 - 100, and 4 - 20 parts of a third type of sand material with a mesh size of 200 - 400.

[0021] Furthermore, the cement includes any one or a combination of more than one of portland cement, sulfoaluminate cement, and aluminate cement.

[0022] A preparation method of an artificial stone with high mechanical properties for preparing the artificial stone with high mechanical properties as described above, including the following steps:

[0023] A. Mix the formula amount of ordinary coarse aggregate, calcium sand, cement, active mineral admixture, water reducing agent, modifier, fiber, and water evenly at a rotation speed of 4 - 20 r / min to obtain a first mixture;

[0024] B. Add the formula amount of suspension stabilizer to the first mixture and mix evenly at a rotation speed of 8 - 40 r / min to obtain a second mixture;

[0025] C. Add the formula amount of extra-coarse aggregate to the second mixture and mix evenly at a rotation speed of 4 - 7 r / min to obtain an artificial stone slurry;

[0026] D. Pour the vacuum-treated artificial stone slurry into a mold, and obtain a plate after vibration compaction; after sealing the plate, obtain the artificial stone with high mechanical properties through steam curing and room temperature curing.

[0027] Furthermore, the vibration compaction time is 40 - 150 s; the curing temperature for steam curing is 60 - 70 °C, and the curing time is 48 - 72 h; the curing time for room temperature curing is 168 - 240 h.

[0028] Furthermore, in step D, the flexural strength of the artificial stone is ≥50 MPa, the compressive strength is ≥170 MPa, and the impact resistance is ≥4 kJ / m 2 .

[0029] The technical solution provided by the present invention may include the following beneficial effects:

[0030] 1. Cement adheres to the surfaces of the extra-coarse aggregate, ordinary coarse aggregate, and calcium sand, wraps and bonds the above three raw materials, causing the artificial stone to bond into a whole, ensuring the strength of the artificial stone. At the same time, the extra-coarse aggregate and the ordinary coarse aggregate are interlocked with each other to form the framework of the artificial stone, providing a supporting effect for the artificial stone; in addition, the calcium sand can also fill the voids in the framework, improving the compactness of the artificial stone, thereby enhancing the mechanical properties such as the flexural strength, compressive strength, and impact resistance of the artificial stone.

[0031] 2. To further improve the strength of the artificial stone, this technical solution introduces active mineral admixtures (such as fly ash, silica fume, slag powder, metakaolin, and steel slag powder, etc.). The active mineral admixtures can not only react with the calcium hydroxide produced by cement hydration to form a gel, strengthening the bonding effect between the extra-coarse aggregate, ordinary coarse aggregate, and calcium sand, but also act as fine aggregates to fill the voids, thereby effectively enhancing the mechanical properties such as the flexural strength, compressive strength, and impact resistance of the artificial stone.

[0032] 3. This technical solution introduces a suspension stabilizer. The suspension stabilizer can effectively prevent the extra-coarse aggregates from approaching and aggregating with each other, enhancing their suspension stability in the system. At the same time, the fibers can not only form a three-dimensional network structure, slowing down the movement of the extra-coarse aggregates, but also ensuring their uniform distribution through dispersion. At the same time, the combination of the extra-coarse aggregate and the ordinary coarse aggregate forms a good aggregate gradation, and the voids between the extra-coarse aggregates are filled with the ordinary coarse aggregate, which is beneficial to forming a more stable suspension system. Specific Embodiments

[0033] This technical solution provides an artificial stone with high mechanical properties, which is obtained by curing the artificial stone slurry;

[0034] Calculated by mass fraction, the artificial stone slurry includes 3 - 60 parts of extra-coarse aggregate, 2 - 40 parts of ordinary coarse aggregate, 17 - 65 parts of calcium sand, 12 - 30 parts of cement, 0.5 - 6 parts of active mineral admixture, 0.01 - 2 parts of suspension stabilizer, 0.3 - 2.5 parts of water reducer, 0.1 - 2 parts of fiber, and 4.0 - 7.5 parts of water;

[0035] The particle size of the extra-coarse aggregate is 12 - 100 cm; the particle size of the ordinary coarse aggregate is 0.1 - 10 cm.

[0036] Aiming at the technical problems existing in the prior art, this technical solution proposes an artificial stone with high mechanical properties. By designing the proportion of the artificial stone slurry and optimizing the raw materials, on the premise of effectively solving the sedimentation problem of the extra-coarse aggregate and ensuring its stable application in the artificial stone, the appearance and mechanical properties of the artificial stone are improved to meet the actual use requirements.

[0037] Specifically, the raw materials of the artificial stone slurry in this technical solution include extra-coarse aggregate, ordinary coarse aggregate, calcium sand, cement, active mineral admixture, suspension stabilizer, water reducer, fiber and water; the cement adheres to the surfaces of the extra-coarse aggregate, ordinary coarse aggregate and calcium sand and wraps and bonds the above three raw materials, enabling the artificial stone to bond into a whole and ensuring the strength of the artificial stone. At the same time, the extra-coarse aggregate and ordinary coarse aggregate are interlocked with each other to form the framework of the artificial stone, providing the function of supporting the artificial stone; in addition, the calcium sand can also fill the voids in the framework, improve the density of the artificial stone, and thus enhance the mechanical properties such as the flexural strength, compressive strength and impact resistance of the artificial stone.

[0038] Secondly, although the use of cement, extra-coarse aggregate, ordinary coarse aggregate and calcium sand is beneficial to improving the mechanical properties of artificial stone, the mechanical properties of the obtained artificial stone are limited and difficult to meet the actual use requirements. Therefore, in order to further improve the strength of artificial stone, this technical solution introduces active mineral admixtures (such as fly ash, silica fume, slag powder, metakaolin and steel slag powder, etc.). The active mineral admixtures can not only react with the calcium hydroxide produced by cement hydration to form a gel, strengthening the bonding effect between the extra-coarse aggregate, ordinary coarse aggregate and calcium sand, but also act as fine aggregates to fill the voids, thus effectively enhancing the mechanical properties such as the flexural strength, compressive strength and impact resistance of the artificial stone.

[0039] Furthermore, although the mutual cooperation of cement, extra-coarse aggregate, ordinary coarse aggregate, calcium sand and active mineral admixture is beneficial to improving the strength of artificial stone, when the strength is too high and the toughness is insufficient, it is easy to cause the artificial stone to crack under the action of external force. Therefore, this technical solution also adds fiber to the raw material formula of the artificial stone slurry. The fiber itself has excellent flexibility and can form a network structure inside the artificial stone, effectively dispersing and transmitting stress, reducing the concentrated stress points generated by the action of external force, thereby enhancing the flexibility and crack resistance of the artificial stone and ensuring the overall mechanical properties of the artificial stone.

[0040] Again, due to the easy settlement problem of the extra-coarse aggregate, it is difficult to ensure the mechanical properties of the artificial stone even with the mutual cooperation of cement, extra-coarse aggregate, ordinary coarse aggregate, calcium sand, active mineral and fiber. Therefore, this technical solution introduces a suspension stabilizer, which can effectively prevent the extra-coarse aggregate from approaching and agglomerating with each other and enhance its suspension stability in the system.

[0041] Furthermore, the fiber can not only form a three-dimensional network structure, slowing down the movement of the extra-coarse aggregate, but also ensure its uniform distribution through the dispersion effect. At the same time, the combination of the extra-coarse aggregate and ordinary coarse aggregate forms a good aggregate gradation, and the voids between the extra-coarse aggregates are filled with ordinary coarse aggregates, which is beneficial to forming a more stable suspension system.

[0042] In summary, through the synergistic effects of suspension stabilizers, fibers, and reasonable aggregate gradations, etc., the present application effectively solves the sedimentation problem of extra-coarse aggregates, avoids the generation of internal voids or holes in artificial stone, and thus ensures the mechanical properties of artificial stone. It should be noted that since the particle size of extra-coarse aggregates is larger than that of ordinary coarse aggregates, if they can maintain suspension stability in the formulation, ordinary coarse aggregates can also maintain suspension stability.

[0043] Furthermore, the solution to the sedimentation problem of extra-coarse aggregates is also beneficial to ensuring the appearance of artificial stone. At the same time, the filling of voids by raw materials such as active mineral admixtures and calcium sand is also conducive to ensuring the appearance of artificial stone. That is, the present application is beneficial to ensuring the appearance of artificial stone through the above-mentioned various effects.

[0044] Even further, the addition of water-reducing agents is crucial for optimizing the fluidity of artificial stone slurries. The specific reasons are as follows: Water-reducing agents improve the fluidity of artificial stone slurries through dispersion and lubrication effects, enabling raw materials such as active mineral admixtures and calcium sand to more effectively fill voids, further enhancing the mechanical properties and appearance of artificial stone.

[0045] Finally, calculated by mass parts, the artificial stone slurry includes 3 - 60 parts of extra-coarse aggregates, 2 - 40 parts of ordinary coarse aggregates, 17 - 65 parts of calcium sand, 12 - 30 parts of cement, 0.5 - 6 parts of active mineral admixtures, 0.01 - 2 parts of suspension stabilizers, 0.3 - 2.5 parts of water-reducing agents, 0.1 - 2 parts of fibers, and 4.0 - 7.5 parts of water. By defining the components of each raw material in the artificial stone slurry, it is beneficial for each raw material to fully play its respective role and is conducive to ensuring the mechanical properties and appearance of artificial stone.

[0046] Preferably, the particle size of the extra-coarse aggregates is 20 - 60 cm; the particle size of the ordinary coarse aggregates is 2 - 8 cm.

[0047] By further defining the particle sizes of the extra-coarse aggregates and ordinary coarse aggregates, it is more conducive to ensuring the performance of the product.

[0048] It should be noted that the water-reducing agent can be a polycarboxylate water-reducing agent, and the specific type is not limited here.

[0049] Further illustration, the length of the fiber is 6 - 12 cm, and the diameter is 60 - 120 mm;

[0050] The fiber includes any one or a combination of steel fibers, basalt fibers, polyethylene fibers, polyoxymethylene fibers, and short-cut carbon fibers.

[0051] When the length and diameter of the fiber are too large, the toughening effect and suspension stability effect are limited; if the length and diameter of the fiber are too large, too many voids are formed, which affects the appearance and mechanical properties of the artificial stone. Therefore, the present technology further optimizes the length and diameter of the fiber, which is beneficial to ensuring the performance of the product.

[0052] Furthermore, steel fibers can significantly improve the flexural strength and compressive strength of artificial stone, and greatly improve its toughness and impact resistance; basalt fibers and polyoxymethylene fibers have excellent properties such as high strength, high modulus, high temperature resistance and corrosion resistance, which are not only beneficial to improving the strength and toughness of artificial stone, but also beneficial to improving the durability of artificial stone; polyethylene fibers and chopped carbon fibers both have the characteristics of light weight and high strength, which are beneficial to improving the toughness and reducing the brittle failure of artificial stone. Therefore, by limiting the fiber to the above types in the present technical solution, it is beneficial to ensure the reinforcement and toughening effects of the fiber. In addition, the types of fibers are preferably multiple. On the premise of being beneficial to ensuring the actual requirements, suitable raw materials can also be selected according to the actual requirements, providing more possibilities and flexibility for its application.

[0053] Further explanation, the active mineral admixture includes any one or a combination of fly ash, silica fume, metakaolin, slag powder and steel slag powder;

[0054] The chemical compositions of the slag powder and the steel slag powder both include silicon dioxide and aluminum trioxide.

[0055] The chemical compositions of fly ash, silica fume, metakaolin, slag powder and steel slag powder contain silicon dioxide, and silicon dioxide can react with calcium hydroxide in the cement hydration product to form calcium silicate hydrate gel. The calcium silicate hydrate gel can not only strengthen the bonding effect between the extra coarse aggregate, ordinary coarse aggregate and calcium sand, but also increase the density of the artificial stone, thereby improving the mechanical properties such as the flexural strength, compressive strength and impact resistance of the artificial stone. In addition, the chemical compositions of fly ash, metakaolin, slag powder and steel slag powder also contain aluminum trioxide, and aluminum trioxide can react with calcium hydroxide in the cement hydration product to form calcium aluminate hydrate gel, which is also beneficial to improving the mechanical properties such as the flexural strength, compressive strength and impact resistance of the artificial stone. In addition, fly ash, silica fume, metakaolin, slag powder and steel slag powder can also be used as fine aggregates to fill voids, which is also beneficial to improving the mechanical properties of artificial stone.

[0056] Preferably, calculated by mass percentage, the chemical composition of the slag powder includes 45-60% of silicon dioxide, 25-30% of aluminum trioxide, 5-10% of iron oxide, 5-10% of calcium oxide, 0.8-1% of magnesium oxide, 0.8-0.9% of sodium oxide, 1.5-2% of potassium oxide and 1.0-1.2% of titanium oxide;

[0057] Calculated by mass percentage, the chemical composition of the steel slag powder includes 12-14% of silicon dioxide, 40-45% of calcium oxide, 3-5% of magnesium oxide, 3-5% of aluminum oxide, 20-25% of iron oxide, 4-6% of manganese oxide, 1-2% of titanium dioxide, 0-1% of potassium oxide, and 2-4% of phosphorus pentoxide.

[0058] In this technical solution, slag powder with a silicon dioxide content of 45-60% and an aluminum oxide content of 25-30% calculated by mass percentage is preferably added to the artificial stone slurry formula, so that the total content of silicon dioxide and aluminum oxide in the artificial stone slurry formula reaches 70-90%, which is beneficial to increasing the content of the gel generated in the formula system, thereby promoting the improvement of the mechanical properties of the artificial stone.

[0059] Preferably, calculated by mass percentage, the chemical composition of the slag powder includes 54.83% of silicon dioxide, 27.16% of aluminum oxide, 6.45% of iron oxide, 7.14% of calcium oxide, 0.97% of magnesium oxide, 0.88% of sodium oxide, 1.5% of potassium oxide, and 1.07% of titanium dioxide;

[0060] Calculated by mass percentage, the chemical composition of the steel slag powder includes 13.8% of silicon dioxide, 43.6% of calcium oxide, 4.8% of magnesium oxide, 4.1% of aluminum oxide, 24.6% of iron oxide, 5.2% of manganese oxide, 1.1% of titanium dioxide, 0.5% of potassium oxide, and 2.3% of phosphorus pentoxide.

[0061] Furthermore, the suspension stabilizer includes any one or a combination of barium-zinc stabilizer, calcium-zinc stabilizer, rare earth calcium-zinc stabilizer, polyurea formaldehyde, polyamide, hydroxyethyl methyl cellulose, hydroxyethyl cellulose, and polyvinyl alcohol.

[0062] Barium-zinc stabilizer, calcium-zinc stabilizer, rare earth calcium-zinc stabilizer, polyamide, hydroxyethyl methyl cellulose, hydroxyethyl cellulose, and polyvinyl alcohol can all effectively increase the charge density on the surface of the extra-coarse aggregate, prompting electrostatic repulsion between the aggregates, and then enhancing their suspension stability in the system. At the same time, barium-zinc stabilizer, calcium-zinc stabilizer, rare earth calcium-zinc stabilizer, polyurea formaldehyde, and polyamide can form a protective film on the surface of the extra-coarse aggregate, using the steric hindrance effect to reduce the aggregation tendency between the extra-coarse aggregates, which is also beneficial to improving the suspension stability. In addition, hydroxyethyl methyl cellulose, hydroxyethyl cellulose, and polyvinyl alcohol are beneficial to increasing the viscosity of the system, hindering the movement of the extra-coarse aggregate in the artificial stone slurry, thereby slowing down the sedimentation rate of the extra-coarse aggregate and improving the suspension stability of the extra-coarse aggregate in the system. Therefore, in this technical solution, the suspension stabilizer is preferably any one or a combination of barium-zinc stabilizer, calcium-zinc stabilizer, rare earth calcium-zinc stabilizer, polyurea formaldehyde, polyamide, hydroxyethyl methyl cellulose, hydroxyethyl cellulose, and polyvinyl alcohol, which is beneficial to ensuring the suspension stability of the coarse aggregate in the system.

[0063] Further explanation: The raw materials of the artificial stone slurry further include a modifier, and the modifier includes any one or a combination of sulfonated naphthalene formaldehyde, nano silica sol, nano silicon dioxide, nano aluminum trioxide, and silane coupling agent;

[0064] Calculated by mass parts, the artificial stone slurry includes 3 - 60 parts of extra - coarse aggregate, 2 - 40 parts of ordinary coarse aggregate, 17 - 65 parts of calcium sand, 12 - 30 parts of cement, 0.5 - 6 parts of active mineral admixture, 0.001 - 2 parts of suspension stabilizer, 0.03 - 2.5 parts of water - reducing agent, 0.05 - 3.5 parts of modifier, 0.001 - 2 parts of fiber, and 4.0 - 7.5 parts of water.

[0065] The modifier includes any one or a combination of sulfonated naphthalene formaldehyde, nano silica sol, nano silicon dioxide, nano aluminum trioxide, and silane coupling agent. Among them, sulfonated naphthalene formaldehyde, as a dispersant, can improve the dispersion of the extra - coarse aggregate in the artificial stone slurry, reduce the agglomeration between the extra - coarse aggregates, reduce the sedimentation tendency of the extra - coarse aggregate, and thus improve its suspension stability.

[0066] The silane coupling agent can be grafted onto the surface of the extra - coarse aggregate, thereby modifying the surface of the extra - coarse aggregate. Modifying the surface of the extra - coarse aggregate with the organosilane coupling agent can not only improve the dispersion of the extra - coarse aggregate in the artificial stone slurry, reduce the agglomeration between the extra - coarse aggregates, but also improve the interfacial properties between the extra - coarse aggregate and the artificial stone slurry, making the extra - coarse aggregate more easily wrapped by the artificial stone slurry, thus reducing the sedimentation tendency of the extra - coarse aggregate and improving its suspension stability.

[0067] The colloidal particles of nano silicon dioxide can form a three - dimensional network structure to wrap the extra - coarse aggregate, improving the suspension stability of the extra - coarse aggregate. At the same time, both nano silica sol (prepared by suspending nano silicon dioxide particles in water or solvent) and the silicon hydroxyl groups on the surface of nano silicon dioxide react with the hydration products of cement, thereby enhancing the bonding strength, and thus improving the mechanical properties such as the flexural strength, compressive strength, and impact resistance of the artificial stone. The aluminum hydroxyl groups on the surface of nano aluminum trioxide can react with the hydration products of cement, thereby enhancing the bonding strength, which is also beneficial to improving the mechanical properties of the artificial stone. In addition, nano silica sol, nano silicon dioxide, and nano aluminum trioxide can all fill the pores, increasing the density of the artificial stone, which is also beneficial to improving the mechanical properties of the artificial stone.

[0068] It should be noted that the silane coupling agent can be γ - aminopropyltriethoxysilane, γ - glycidyletheroxypropyltrimethoxysilane, and γ - methacryloxypropyltrimethoxysilane, and the specific types are not limited herein.

[0069] Further explanation, calculated by mass parts, the calcium sand includes 5-20 parts of a first type of sand material with a mesh size of 70-80, 8-25 parts of a second type of sand material with a mesh size of 90-100, and 4-20 parts of a third type of sand material with a mesh size of 200-400.

[0070] In this technical solution, by optimizing the mesh size and proportion of various types of sand materials, it is beneficial to improve the density of artificial stone, thereby improving its appearance and mechanical properties.

[0071] Further explanation, the cement includes any one or a combination of more of portland cement, sulfoaluminate cement, and aluminate cement.

[0072] Portland cement, sulfoaluminate cement, and aluminate cement can all generate a large amount of hydration products and produce strength. The above hydration products have excellent filling and bonding properties, can fill the voids and holes in artificial stone, improve the density of artificial stone, and are beneficial to improving its appearance and mechanical properties.

[0073] A preparation method of artificial stone with high mechanical properties, used to prepare the above-mentioned artificial stone with high mechanical properties, includes the following steps:

[0074] A. Mix the formula amount of ordinary coarse aggregate, calcium sand, cement, active mineral admixture, water reducer, modifier, fiber, and water evenly at a rotation speed of 4-20 r / min to obtain a first mixture;

[0075] B. Add the formula amount of suspension stabilizer to the first mixture and mix evenly at a rotation speed of 8-40 r / min to obtain a second mixture;

[0076] C. Add the formula amount of extra-coarse aggregate to the second mixture and mix evenly at a rotation speed of 4-7 r / min to obtain artificial stone slurry;

[0077] D. Pour the vacuum-treated artificial stone slurry into a mold, and obtain a plate after vibration pressing; the plate is sealed and then subjected to steam curing and room temperature curing to obtain artificial stone with high mechanical properties.

[0078] This technical solution also proposes a preparation method of artificial stone with high mechanical properties, which has simple steps and strong operability, and is beneficial to ensuring the relevant properties of artificial stone during the preparation process.

[0079] Specifically, in step A, first mix the remaining components except the suspension stabilizer and the extra-coarse aggregate, and limit the stirring speed, which not only ensures the full dispersion and fusion of various raw materials, but also helps to control the fluidity of the first mixture within the range of 90-140 mm, making the first mixture form a stable and easy-to-adjust viscosity base slurry, providing a good basis for the subsequent steps.

[0080] In step B, a suspension stabilizer is added to the first mixture, and the stirring speed is limited so that the fluidity of the second mixture is in the range of 70 to 110 mm, making the second mixture have both high viscosity and a certain fluidity, so that when extra-coarse aggregate is added to the second mixture, the extra-coarse aggregate can be stably suspended.

[0081] In step C, the stirring speed is limited. This can not only prevent the extra-coarse aggregate from settling and stratifying due to too fast stirring, thus being beneficial to improving the suspension stability of the extra-coarse aggregate, but also control the fluidity of the artificial stone slurry within the range of 10 to 70 mm, realizing the flow filling and densification of the artificial stone slurry during the subsequent vibration compaction process, thereby ensuring the performance of the artificial stone.

[0082] In step D, the vacuum treatment can discharge the gas in the artificial stone slurry, effectively reducing the gas content in the artificial stone slurry, thereby reducing the pores and holes in the artificial stone prepared from the artificial stone slurry, and further improving the performance of the artificial stone.

[0083] Preferably, the specific method of the vacuum treatment is: placing the artificial stone slurry in a vacuum device and reducing the internal gas pressure to -0.1 to -0.05 kPa through the vacuum operation.

[0084] Further explanation, in step D, the vibration compaction time of the vibration compaction is 40 to 150 s; the curing temperature of the steam curing is 60 to 70 °C, and the curing time is 48 to 72 h; the curing time of the room temperature curing is 168 to 240 h.

[0085] In a preferred embodiment of the present technical solution, in step B, the vibration compaction time of the vibration compaction is 40 to 150 s to ensure the performance of the product and reduce the loss during its production process; if the vibration compaction time is too low, the resulting artificial stone product will not be dense enough, with many pores, affecting the appearance and mechanical properties of the product; if the vibration compaction time is too long, the extra-coarse aggregate is likely to settle, affecting the appearance and mechanical properties of the product.

[0086] Furthermore, in the curing temperature of the steam curing, the curing temperature is 60 to 70 °C, which is convenient for accelerating the curing, improving the density of the product, reducing the fine pores, and improving the appearance and mechanical properties of the product; in addition, the steam curing time is 48 to 72 h, and the room temperature curing time is 168 to 240 h, ensuring the performance of the artificial stone.

[0087] Further explanation, in step D, the flexural strength of the artificial stone is ≥50 MPa, the compressive strength is ≥170 MPa, and the impact resistance is ≥4 kJ / m 2 。

[0088] In this technical solution, the bending strength of the artificial stone is ≥50 MPa, the compressive strength is ≥170 MPa, and the impact resistance is ≥4 kJ / m 2 , which not only has high mechanical properties but also has a good appearance.

[0089] The technical solution of the present invention will be further described below through specific embodiments.

[0090] Example 1

[0091] A. Mix 30 parts of ordinary coarse aggregate with a particle size of 8 cm, 40 parts of calcium sand, 20 parts of sulfoaluminate cement, 3 parts of slag powder, 0.5 part of polycarboxylate water reducer, 3 parts of nano-silica with a particle size of 20 nm, 1.5 parts of basalt fiber, and 5 parts of water evenly at a rotation speed of 10 r / min to obtain a first mixture; the length of the basalt fiber is 8 cm and the diameter is 80 mm; calculated by mass fraction, the calcium sand includes 8 parts of a first type of sand with a mesh size of 70-80, 12 parts of a second type of sand with a mesh size of 90-100, and 18 parts of a third type of sand with a mesh size of 200-400; calculated by mass percentage, the chemical composition of the slag powder includes 54.83% of silicon dioxide, 27.16% of aluminum oxide, 6.45% of iron oxide, 7.14% of calcium oxide, 0.97% of magnesium oxide, 0.88% of sodium oxide, 1.5% of potassium oxide, and 1.07% of titanium oxide;

[0092] B. Add 1 part of hydroxyethyl methyl cellulose to the first mixture and mix evenly at a rotation speed of 20 r / min to obtain a second mixture;

[0093] C. Add 40 parts of extra-coarse aggregate with a particle size of 40 cm to the second mixture and mix evenly at a rotation speed of 4 r / min to obtain artificial stone slurry;

[0094] D. Pour the vacuum-treated artificial stone slurry into a mold, vibrate and press for 100 s to obtain a plate; after sealing the plate, steam-cure it at 70 °C for 72 h and cure it at room temperature for 200 h to obtain artificial stone with high mechanical properties; the specific method of vacuum treatment is: place the artificial stone slurry in a vacuum device and reduce the internal gas pressure to -0.1 to -0.05 kPa through vacuum pumping.

[0095] Example 2

[0096] A. Mix 10 parts of ordinary coarse aggregate with a particle size of 5 cm, 35 parts of calcium sand, 18 parts of portland cement, 3 parts of fly ash, 1 part of polycarboxylate superplasticizer, 0.5 part of γ-aminopropyltriethoxysilane, 1 part of steel fiber, and 6 parts of water evenly at a rotation speed of 8 r / min to obtain a first mixture; the length of the steel fiber is 7 cm and the diameter is 60 mm; calculated by mass parts, the calcium sand includes 10 parts of a first-class sand material with a mesh size of 70-80, 15 parts of a second-class sand material with a mesh size of 90-100, and 12 parts of a third-class sand material with a mesh size of 200-400;

[0097] B. Add 2 parts of polyurea formaldehyde to the first mixture and mix evenly at a rotation speed of 10 r / min to obtain a second mixture;

[0098] C. Add 40 parts of extra-coarse aggregate with a particle size of 30 cm to the second mixture and mix evenly at a rotation speed of 5 r / min to obtain artificial stone slurry;

[0099] D. Pour the vacuum-treated artificial stone slurry into a mold, vibrate and press for 80 s to obtain a plate; after sealing the plate, cure it in steam at 60 °C for 48 h and cure it at room temperature for 168 h to obtain artificial stone with high mechanical properties; the specific method of vacuum treatment is: place the artificial stone slurry in a vacuum device and reduce the internal gas pressure to -0.1 to -0.05 kPa through vacuum pumping operation.

[0100] Example 3

[0101] A. Mix 35 parts of ordinary coarse aggregate with a particle size of 8 cm, 60 parts of calcium sand, 30 parts of aluminate cement, 5 parts of steel slag powder, 2 parts of polycarboxylate superplasticizer, 3 parts of nano-aluminum trioxide with a particle size of 40 nm, 1 part of polyethylene fiber, and 4.0 - 7.5 parts of water evenly at a rotation speed of 18 r / min to obtain a first mixture; the length of the polyethylene fiber is 9 cm and the diameter is 100 mm; calculated by mass parts, the calcium sand includes 8 parts of a first-class sand material with a mesh size of 70-80, 20 parts of a second-class sand material with a mesh size of 90-100, and 20 parts of a third-class sand material with a mesh size of 200-400; calculated by mass percentage, the chemical composition of the steel slag powder includes 13.8% of silicon dioxide, 43.6% of calcium oxide, 4.8% of magnesium oxide, 4.1% of aluminum oxide, 24.6% of iron oxide, 5.2% of manganese oxide, 1.1% of titanium dioxide, 0.5% of potassium oxide, and 2.3% of phosphorus pentoxide;

[0102] B. Add 1 part of polyvinyl alcohol to the first mixture and mix evenly at a rotation speed of 10 r / min to obtain a second mixture;

[0103] C. Add 50 parts of extra-coarse aggregate with a particle size of 80 cm to the second mixture and mix evenly at a rotation speed of 7 r / min to obtain artificial stone slurry;

[0104] D. Pour the artificial stone slurry after vacuum treatment into a mold, and obtain a plate after vibrating and pressing for 50 s; seal the plate and steam-cure it at 70 °C for 48 h and cure it at room temperature for 240 h to obtain artificial stone with high mechanical properties; the specific method of vacuum treatment is: place the artificial stone slurry in a vacuum device, and reduce the gas pressure inside it to -0.1 to -0.05 kPa through vacuum pumping operation.

[0105] Example 4

[0106] A. Mix 30 parts of ordinary coarse aggregate with a particle size of 5 cm, 30 parts of calcium sand, 18 parts of cement, 4 parts of silica fume, 0.8 part of polycarboxylate superplasticizer, 2 parts of sulfonated naphthalene formaldehyde, 0.7 part of short-cut carbon fiber, and 6 parts of water evenly at a rotation speed of 8 r / min to obtain a first mixture; the length of the short-cut carbon fiber is 9 cm and the diameter is 90 mm; calculated by mass fraction, the calcium sand includes 10 parts of a first-class sand material with a mesh size of 70-80, 16 parts of a second-class sand material with a mesh size of 90-100, and 8 parts of a third-class sand material with a mesh size of 200-400;

[0107] B. Add 0.5 part of hydroxyethyl methyl cellulose to the first mixture and mix evenly at a rotation speed of 32 r / min to obtain a second mixture;

[0108] C. Add 8 parts of extra-coarse aggregate with a particle size of 60 cm to the second mixture and mix evenly at a rotation speed of 6 r / min to obtain artificial stone slurry;

[0109] D. Pour the artificial stone slurry after vacuum treatment into a mold, and obtain a plate after vibrating and pressing for 100 s; seal the plate and steam-cure it at 65 °C for 60 h and cure it at room temperature for 220 h to obtain artificial stone with high mechanical properties; the specific method of vacuum treatment is: place the artificial stone slurry in a vacuum device, and reduce the gas pressure inside it to -0.1 to -0.05 kPa through vacuum pumping operation.

[0110] Example 5

[0111] A. Mix 10 parts of ordinary coarse aggregate with a particle size of 6 cm, 20 parts of calcium sand, 15 parts of cement, 4 parts of metakaolin, 1.5 parts of polycarboxylate superplasticizer, 1.2 parts of γ-aminopropyltriethoxysilane, 1 part of polyoxymethylene fiber, and 7 parts of water evenly at a rotation speed of 8 r / min to obtain a first mixture; the length of the polyoxymethylene fiber is 11 cm and the diameter is 100 mm; calculated by mass fraction, the calcium sand includes 14 parts of a first-class sand material with a mesh size of 70-80, 18 parts of a second-class sand material with a mesh size of 90-100, and 15 parts of a third-class sand material with a mesh size of 200-400;

[0112] B. Add 0.1 part of barium-zinc stabilizer to the first mixture and mix evenly at a rotation speed of 20 r / min to obtain a second mixture;

[0113] C. Add 18 parts of extra-coarse aggregate with a particle size of 30 cm to the second mixture, and mix evenly at a rotation speed of 5 r / min to obtain artificial stone slurry;

[0114] D. Pour the artificial stone slurry after vacuum treatment into a mold, and obtain a plate after vibrating and pressing for 60 s; seal the plate and steam-cure it at 70 °C for 72 h and cure it at room temperature for 220 h to obtain artificial stone with high mechanical properties; the specific method of vacuum treatment is: place the artificial stone slurry in a vacuum device, and reduce the gas pressure inside it to -0.1 to -0.05 kPa through vacuum pumping operation.

[0115] Comparative Example 1

[0116] The preparation method and raw materials of Comparative Example 1 are the same as those of Example 1, except that the suspension stabilizer is not added to the artificial stone slurry formula in Comparative Example 1.

[0117] Comparative Example 2

[0118] The preparation method and raw materials of Comparative Example 2 are the same as those of Example 1, except that the fiber is not added to the artificial stone slurry formula in Comparative Example 2.

[0119] Use the preparation methods in the above examples and comparative examples to prepare artificial stone respectively. Observe the appearance of the artificial stone with the naked eye, and test the flexural strength, compressive strength and impact resistance of the artificial stone according to the test standard of "GB / T 35160 Test Methods for Synthetic Stone". The results are shown in Table 1 below.

[0120] Table 1 Test results of related properties of artificial stone

[0121] Experiment number Appearance Flexural strength (MPa) Compressive strength (MPa) <![CDATA[Impact resistance (kJ / m 2 )]]> Example 1 Basically without holes and voids 52.39 175.19 4.15 Example 2 Basically without holes and voids 51.96 173.22 4.09 Example 3 Basically without holes and voids 50.87 171.09 4.03 Example 4 Basically without holes and voids 51.32 172.09 4.08 Example 5 Basically without holes and voids 50.45 171.62 4.04 Comparative example 1 With obvious holes and voids 48.72 167.91 3.88 Comparative example 2 With obvious holes and voids 42.55 153.80 3.79

[0122] From the performance test results in Table 1, it can be seen that for the artificial stone prepared by the preparation method of an artificial stone with high mechanical properties in the present technical solution, its flexural strength ≥ 50 MPa, compressive strength ≥ 170 MPa, and impact resistance ≥ 4 kJ / m 2 , not only has high mechanical properties, but also has good appearance, meeting the use requirements.

[0123] In Comparative Example 1, due to the lack of suspension stabilizer, and in Comparative Example 2, due to the lack of fiber, the suspension stability of the extra-coarse aggregate is poor, making it easy to settle in the slurry, resulting in voids or holes in the prepared artificial stone, affecting its appearance and mechanical properties. In addition, due to the lack of fiber in Comparative Example 2, the artificial stone obtained in Comparative Example 2 has insufficient toughness, further affecting its flexural strength and impact resistance.

[0124] The technical principle of the present invention has been described above in connection with specific embodiments. These descriptions are only for explaining the principle of the present invention and should not be construed in any way as a limitation on the protection scope of the present invention. Based on the explanations herein, those skilled in the art can readily conceive of other specific embodiments of the present invention without creative efforts, and these embodiments will all fall within the protection scope of the present invention.

Claims

1. An artificial stone with high mechanical properties, characterized in that, It is obtained by curing and solidifying artificial stone slurry; Calculated by mass parts, the artificial stone slurry includes 3 - 60 parts of extra - coarse aggregate, 2 - 40 parts of ordinary coarse aggregate, 17 - 65 parts of calcium sand, 12 - 30 parts of cement, 0.5 - 6 parts of active mineral admixture, 0.01 - 2 parts of suspension stabilizer, 0.3 - 2.5 parts of water - reducing agent, 0.1 - 2 parts of fiber and 4.0 - 7.5 parts of water; The particle size of the extra - coarse aggregate is 12 - 100 cm; the particle size of the ordinary coarse aggregate is 0.1 - 10 cm.

2. The artificial stone with high mechanical properties according to claim 1, characterized in that, The length of the fiber is 6 - 12 cm, and the diameter is 60 - 120 mm; The fiber includes any one or a combination of more than one of steel fiber, basalt fiber, polyethylene fiber, polyoxymethylene fiber and chopped carbon fiber.

3. The artificial stone with high mechanical properties according to claim 1, wherein The active mineral admixture includes any one or a combination of more than one of fly ash, silica fume, metakaolin, slag powder and steel slag powder; The chemical compositions of the slag powder and the steel slag powder both include silicon dioxide and aluminum oxide.

4. A artificial stone with high mechanical properties according to claim 1, characterized in that, The suspension stabilizer includes any one or a combination of more than one of barium - zinc stabilizer, calcium - zinc stabilizer, rare - earth calcium - zinc stabilizer, polyurea formaldehyde, polyamide, hydroxyethyl methyl cellulose, hydroxyethyl cellulose and polyvinyl alcohol.

5. The artificial stone with high mechanical properties according to claim 1, wherein The raw materials of the artificial stone slurry further include a modifier, and the modifier includes any one or a combination of more than one of sulfonated naphthalene formaldehyde, nano - silica sol, nano - silicon dioxide, nano - aluminum oxide and silane coupling agent; Calculated by mass parts, the artificial stone slurry includes 3 - 60 parts of extra - coarse aggregate, 2 - 40 parts of ordinary coarse aggregate, 17 - 65 parts of calcium sand, 12 - 30 parts of cement, 0.5 - 6 parts of active mineral admixture, 0.001 - 2 parts of suspension stabilizer, 0.03 - 2.5 parts of water - reducing agent, 0.05 - 3.5 parts of modifier, 0.001 - 2 parts of fiber and 4.0 - 7.5 parts of water.

6. The artificial stone with high mechanical properties according to claim 1, characterized in that, Calculated by mass parts, the calcium sand includes 5 - 20 parts of first - class sand with a mesh size of 70 - 80, 8 - 25 parts of second - class sand with a mesh size of 90 - 100 and 4 - 20 parts of third - class sand with a mesh size of 200 - 400.

7. The artificial stone with high mechanical properties according to claim 1, characterized in that, The cement includes any one or a combination of more than one of portland cement, sulphoaluminate cement and aluminate cement.

8. A preparation method of artificial stone with high mechanical properties, characterized in that, For preparing the artificial stone with high mechanical properties as described in any one of claims 5 - 7, it includes the following steps: A. Mix the formula - amount of ordinary coarse aggregate, calcium sand, cement, active mineral admixture, water - reducing agent, modifier, fiber and water evenly at a rotation speed of 4 - 20 r / min to obtain a first mixture; B. Add the formula - amount of suspension stabilizer to the first mixture and mix evenly at a rotation speed of 8 - 40 r / min to obtain a second mixture; C. Add the formula - amount of extra - coarse aggregate to the second mixture and mix evenly at a rotation speed of 4 - 7 r / min to obtain artificial stone slurry; D. Pour the vacuum - treated artificial stone slurry into a mold, obtain a plate after vibration compaction; after sealing the plate, obtain the artificial stone with high mechanical properties through steam curing and room - temperature curing.

9. The preparation method of an artificial stone with high mechanical properties according to claim 8, characterized in that, In step D, the vibration and pressing time is 40 to 150 s; the curing temperature for steam curing is 60 to 70 °C, and the curing time is 48 to 72 h; the curing time for room temperature curing is 168 to 240 h.

10. The preparation method of an artificial stone with high mechanical properties according to claim 8, characterized in that, In step D, the bending strength of the artificial stone ≥ 50 MPa, the compressive strength ≥ 170 MPa, and the impact resistance ≥ 4 kJ / m 2 .