A method for manufacturing a synthetic resin fiber-reinforced thin natural-texture stone material

Abstract

This invention provides a method for manufacturing thin-film natural textured stone reinforced with synthetic resin fibers, comprising the following steps: S1, raw stone trimming: after mining, the raw stone is trimmed into regular cuboids and polished smooth; S2, applying reinforcing fibers: fiber reinforcement material is applied to the surface of the cuboids using a resin curing method; S3, stone cutting; S4, stone reinforcement. This invention achieves the softness and elasticity of composite sheets by reinforcing the stone with resin curing, resulting in bendable thin-layer stone. This effectively solves the problem of the lack of flexible stone lamination in existing technologies, ensuring sufficient bendability and flexibility when bending. Furthermore, the prepared stone possesses advantages such as fire resistance, chemical corrosion resistance, high temperature resistance, and high gloss. It can save a significant amount of natural stone resources.

Description

Technical Field

[0001] This invention relates to a method for manufacturing thin-film natural textured stone reinforced with synthetic resin fibers, belonging to the field of stone production technology. Background Technology

[0002] In practice, it is often necessary to apply thin layers of stone to irregularly shaped surfaces. This avoids the inconvenience of installation caused by the excessive weight of the entire stone and also creates the surface effect of the stone material.

[0003] However, current technology lacks methods for softening and improving the elasticity of stone. For these needs, the common methods are printing textured patterns onto the stone or cutting irregularly shaped surfaces to match the desired shape. While textured patterns address the visual appeal, they don't solve the tactile issue. Cutting the stone to match its shape is too costly and carries a high risk of failure. Thinning natural stone using current technology leads to breakage, and the thicker cutting tools result in significant stone loss during cutting and polishing, further increasing costs. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention provides a method for manufacturing thin-film natural textured stone reinforced with synthetic resin fibers. This method achieves flexibility and elasticity by strengthening the stone through resin curing, resulting in a bendable thin-film stone, effectively solving the problem of the lack of flexible stone veneers in existing technologies. Furthermore, the method utilizes a chisel-cutting technique to eliminate the need for cutting stone, significantly saving natural stone.

[0005] The present invention is achieved through the following technical solutions.

[0006] This invention provides a method for manufacturing thin-film natural textured stone reinforced with synthetic resin fibers, comprising the following steps: S1. Raw stone cutting: After the raw stone is mined, it is cut into regular cuboids, polished and smoothed to obtain natural stone, and clamped with clamps. S2. Applying reinforcing fibers: Applying fiber-reinforcing materials to the surface of the cuboid using a resin curing method; allowing the resin to penetrate into the cracks of the natural stone and reinforce it. S3. Stone cutting: The cuboid with the resin fiber layer already cured is cut into thin stone layers. The cutting trajectory is parallel to the fiber reinforcement material to obtain a thin layer of resin fiber composite natural stone. S4. Stone reinforcement: Use an arc mold to bend the resin fiber composite natural stone thin layer to expose the cracks in the natural stone to facilitate resin penetration. Then, flatten the resin fiber composite natural stone thin layer with resin penetration and squeeze out excess resin. Cure the resin that has penetrated the stone and color the resin.

[0007] The surface flatness of the polished surface in step S1 is 0.1~0.2mm.

[0008] In step S2, the fiber reinforcement material is a fabric woven from glass fiber, basalt fiber, or carbon fiber.

[0009] In step S2, the resin used is acrylic resin, epoxy resin, unsaturated polyester resin or polyurethane resin, and the curing method is determined according to the type of resin used and is at least one of hot air curing, room temperature curing and ultraviolet light curing.

[0010] In step S3, the cutting thickness is 3~5mm including grinding allowance.

[0011] In step S3, a long cutting tool made of cemented carbide or PCD alloy is used for cutting. The tool is welded to the tool body using copper as a binder and high-frequency heating.

[0012] In step S4, the fiber-reinforced material side of the thin-layer stone is bent in a way that it is tightly attached to the arc-shaped mold, so that the cracks of the natural stone are exposed on the reverse side to facilitate resin penetration.

[0013] In step S4, the resin that has penetrated the stone is cured by photocuring acrylate resin.

[0014] When curing the resin that has penetrated the stone, the resin viscosity is controlled to be 1000 Pa·s, the temperature resistance is above 200℃, the curing agent is 1~5% photoinitiator, and 0.5~2% defoamer is added, and an adhesion promoter is added to the resin.

[0015] In step S4, when the resin penetrating the stone is cured, excess resin is reused. After the resin penetrating the stone is cured, it is coarsely ground until the grinding thickness is reached, and then finely ground and polished. Light-cured resin is scraped with a scraper rod and then polished.

[0016] The beneficial effects of this invention are as follows: by strengthening the softness and elasticity of stone through resin curing, a flexible thin-layer stone can be obtained, which can effectively solve the problem of the lack of flexible stone veneer in the prior art, ensuring that the thin-layer stone has sufficient flexibility and bendability when bent, and the prepared stone has advantages such as fire resistance, chemical corrosion resistance, high temperature resistance, and high gloss. Attached Figure Description

[0017] Figure 1 This is a flowchart illustrating at least one embodiment of the present invention; Figure 2 yes Figure 1 A schematic diagram of the stone cutting fixtures and tools in relation to the raw stone during stone cutting. Figure 3 yes Figure 1 A schematic diagram showing the process of spreading the stone cut off by the shovel onto an arc-shaped mold during the reinforcement of the medium-sized stone. Figure 4 This is a schematic diagram of the stone structure after the final product has been unfolded and flattened.

[0018] In the diagram: 1-Knife, 2-Natural stone, 3-Clamp, 4-Resin fiber layer, 5-Arc mold, 6-Resin fiber composite natural stone thin layer, 7-Thin layer raw stone, 8-Rinse-rich layer. Detailed Implementation

[0019] The technical solution of the present invention is further described below, but the scope of protection is not limited to what is described.

[0020] The first embodiment of the present invention relates to a method for manufacturing a thin-film natural textured stone reinforced with synthetic resin fibers, comprising the following steps: S1. Raw stone cutting: After the raw stone is mined, it is cut into regular cuboids, polished and smoothed to obtain natural stone material 2, and clamped with clamps 3 to retain a certain degree of roughness; S2. Applying reinforcing fibers: Remove dust and residue from the surface of the stone to clean the cracks on the surface of the natural stone 2, so that the resin can penetrate into the cracks. After cleaning, apply the fiber reinforcement material to the surface of the cuboid using a resin curing method, ensuring that it is flat and uniform. Then, use a low-viscosity resin to penetrate into the cracks of the natural stone 2 for reinforcement, thus obtaining the resin fiber layer 4. This operation must ensure that the resin fiber layer is flat and uniform while controlling the thickness within a certain range. S3, Stone Cutting: The raw stone obtained in S2 is cut into thin layers of stone by a process equivalent to planing and shoveling, with the solidified resin fiber cuboid being cut into thin layers of stone. The cutting trajectory is parallel to the plane formed by the fiber reinforcement material to obtain a thin layer of resin fiber composite natural stone 6. This processing method results in a whole piece of stone with cracks due to the planing and shoveling. When the thin layer of natural stone with resin fiber layer is removed from the raw stone, a large number of cracks will be generated in the natural stone. The reinforcement of the resin fiber prevents the cracked raw stone pieces from falling off. S4. Stone Reinforcement: The thin slices of natural stone cut off during the cutting process produce numerous cracks. Using a blower, debris is removed from the cracks. An arc-shaped mold is used to bend the thin layer of stone to open the cracks and allow resin to penetrate. Simultaneously, the slab is laid flat to squeeze out excess resin, which is then scraped off. The slab is then placed on a flat surface to allow the resin to cure. Excess resin can be reused. Depending on the decorative needs, the resin can be colored to create a complementary, uniformly colored crack effect in addition to the original stone, resulting in a more even texture.

[0021] The second embodiment of the present invention is largely the same as the first embodiment, except that the surface flatness in step S1 is 0.1~0.2mm. The cured resin fiber natural thin-layer stone is adhered to another platform with double-sided tape or hot melt adhesive, and then polished using a rotating grinding wheel from coarse to fine, with a grinding amount of 1-2mm. Next, a resin layer of several tens of micrometers thick is evenly applied with a squeegee and cured, followed by polishing until a mirror finish is achieved. The final product thickness is approximately 2-3mm (including the 1mm resin fiber layer).

[0022] In step S2, the fiber reinforcement material is a fabric woven from glass fiber, basalt fiber, or carbon fiber.

[0023] In step S2, the acrylic resin used is epoxy resin, unsaturated polyester resin, or polyurethane resin. The curing method is determined according to the type of resin used and is at least one of hot air curing, room temperature curing, and ultraviolet light curing. Light curing is preferred for faster, more precise, and more efficient application.

[0024] In step S3, the cutting thickness is 3~5mm including grinding allowance.

[0025] In step S3, a long cutting tool 1 made of cemented carbide or PCD alloy is used for cutting. The tool is welded to the tool body using copper as a binder and high-frequency heating.

[0026] The third embodiment of the present invention is largely the same as the first embodiment, except that in step S4, after bending the thin-layer stone with the fiber-reinforced material side tightly against the arc mold, the stone cracks after bending and opening are impregnated with resin and then placed flat on the plane. Excess resin is squeezed out. At this time, uncured resin can be collected with a tool and can continue to be used. Figure 3 The resin fiber composite natural stone thin layer 6, obtained by planing and scraping, consists of a resin fiber layer 4 and a thin layer of raw stone 7.

[0027] In step S4, the resin is cured by light-curing acrylic resin. The raw resin fiber composite natural stone thin layer 6, which is reinforced on the front, is coarsely ground and then finely ground until a certain degree of flatness is achieved.

[0028] During resin curing, in order to facilitate resin wetting and control the resin viscosity to below 1000 Pa·s and the temperature resistance to around 200℃, the curing agent uses 1~5% photoinitiator and 0.5~2% defoamer. In order to ensure the resin's adhesion and reinforcement to the stone, 1~5% adhesion promoter is mixed into the resin.

[0029] Before the resin is cured, lay the resin fiber composite natural stone thin layer 6 flat and squeeze out the excess resin. Use a flat scraper made of silicone rubber or polyurethane rubber to scrape off the excess resin. Then cure the resin fiber composite natural stone thin layer 6 that has been infiltrated with reinforcing resin. Finally, use a wire rod to evenly scrape on a layer of light-cured resin and cure this resin-rich layer. Then continue fine grinding and polishing until a mirror finish is achieved.

[0030] Applying resin to the surface of natural stone can achieve a certain thickness, forming a resin layer that completely covers the natural stone. Furthermore, the resin on the surface meets the resin within the cracks of the natural stone, creating a bonding effect similar to riveting. Excess resin on the stone surface is then ground and polished to achieve a uniform smoothness. This results in a consistent high-gloss finish, which is significantly better than the inconsistent smoothness that can be achieved on natural stone surfaces due to variations in texture and material, resulting in a superior visual appeal.

[0031] Furthermore, in step S4, the thin stone is impregnated with resin while bent, then flattened to squeeze out excess resin and scraped off for reuse. The resin is then evenly applied using a squeegee and allowed to cure before coarse grinding until the desired thickness is achieved, followed by fine grinding and polishing. A light-cured resin layer with a thickness of several micrometers is then applied using a squeegee and polished again. This final layer of resin gives the stone surface a uniform high gloss and forms a chemical-resistant protective layer.

[0032] The fourth embodiment of the present invention, in conjunction with the above embodiments, specifically adopts the following steps: Step 1: Raw stone mining. After mining, the raw stone is cut into regular cuboids. The cut surfaces of the cuboids need to be polished smooth (surface smoothness: the difference between the highest and lowest points of the unevenness should be controlled within 0.1-0.2mm).

[0033] Step 2: Applying Reinforcing Fibers: Apply fiber-reinforcing material to the smooth surface of the cuboid. The fibers can be woven fabrics made of glass fiber, basalt fiber, carbon fiber, etc. The adhesive resins used are acrylic resins, epoxy resins, unsaturated polyester resins, polyurethane resins, and their corresponding curing agents. The resin viscosity should be as low as possible during application to facilitate penetration into the stone, increasing the adhesion between the fibers and the stone, as well as between stones themselves. The curing method depends on the selected resin and curing agent; it can be hot air curing, room temperature curing, or ultraviolet light curing.

[0034] Step 3: Stone Cutting: Thin-cut stone is cut on the resin-cured stone. Specialized cutting tools are used, such as long blades made of cemented carbide or PCD alloy. The blades are welded to a powerful, moving frame using copper as a binder and high-frequency heating. The cutting thickness of 3-5mm is to account for grinding, polishing, and other machining allowances. The specific method is as follows: The alloy blade moves to the left along the cutting direction, its trajectory parallel to the reinforcing fiberglass mesh layer. The natural stone is pre-fixed with a clamp. The sharp blade and powerful motor easily and completely remove the reinforcing mesh layer and the natural stone layer from the surface of the entire stone. Due to the high bonding strength of the mesh layer, it is firmly bonded to the stone.

[0035] Step 4: Stone Reinforcement: The reinforced stone can be bent significantly along the axial direction of the curved mold. However, this significant bending will cause the cracks formed during the scraping process to widen and create more cracks. Because the adhesive resin has high bonding strength, the scraped stone will adhere firmly to the fiberglass mesh. During the scraping process, some stone will be damaged, causing ice cracks on the material surface. Therefore, resin needs to be used to further penetrate the cracks and reinforce the stone. The method is as follows: The cut stone is spread onto the curved mold, with the fiber layer applied against the mold surface and the stone side facing outwards. At this time, the cracks will open, facilitating resin impregnation. First, use an air gun to blow away the residue. Then, use light-cured acrylic resin to penetrate the cracks. The resin viscosity should be controlled below 1000 Pa·s. The resin should be fully transparent and resistant to temperatures around 200℃. Add 1-5% of photoinitiator 184 or 1733, 0.5-2% of defoamer, and 1-5% of adhesion promoter. Use a flat silicone rubber or polyurethane rubber scraper to apply the resin to the surface of the composite material, ensuring that every crack is penetrated by the resin.

[0036] After the above operations are completed, the thin sheet is flatly attached to the plate with the resin-coated side facing up. After the surface is straight and smooth, the resin that has seeped into the cracks is squeezed out. This process is also a process of impregnation and degassing. This type of bonding uses acrylic resin esters, which have strong adhesion to stone. Its toughness ensures that the thin sheet of natural stone will not crack when bent at a large angle, and gives the stone softness and elasticity, improving the drawback of natural stone cracking when the bending range is too large. Even if the original stone cracks are partially broken off, they will be filled by resin impregnation and composite. The resin is then repeatedly scraped and coated until smooth using a scraper with controllable thickness. The thickness can reach 20-50 micrometers. Excess resin is scraped off, and then cured with ultraviolet light or mercury lamp for a few seconds to a dozen seconds. After being fully cured for several hours, the thin sheet is temporarily glued and fixed with a plate. The stone surface with excess resin layer is ground smooth. After initial grinding, fine grinding, and polishing, a stone with excellent effect is obtained. By controlling the grinding and polishing of the resin-coated surface, a smoothness exceeding that of ordinary stone is achieved by leaving a pure resin layer of several micrometers.

[0037] The protective coating connects with the resin deep within the stone's cracks, forming a structure with numerous rivets that prevent it from easily peeling off the natural stone surface. This rivet-like structure further ensures sufficient flexibility and suppleness when the thin material is bent. The stone, after planing, can be repeatedly covered with resin fiber cloth on the surface left from the previous planing process, thus repeatedly creating thin layers of natural marble.

[0038] Compared to existing sawing methods, the method of cutting natural stone by chiseling avoids the loss of stone in the saw kerf and the unevenness caused by saw tool deviations. More stone can be produced from the same volume of stone. Stone produced using this method has advantages such as fire resistance, chemical corrosion resistance, high temperature resistance, and high gloss. The thickness of the natural stone obtained using this method is only 2-4mm, with a fiber resin reinforcement layer of about 1mm and the natural stone portion being 1-3mm. Due to the thinness of the stone, it has a translucent effect and retains all the properties of natural stone. This sheet can be rolled for transport and can also be bent into shape. After obtaining partial resin penetration into the cracks and complete UV curing, it undergoes coarse and fine grinding to achieve a certain degree of flatness. Then, a certain thickness of UV-cured resin is applied with a wire rod, cured, and then finely ground again. If a visible effect of uniform small cracks is required, this adhesive resin can be colored to create an artificial texture effect in addition to natural grain. This resin is colorless and transparent, so after curing, the resin is almost invisible.

Claims

1. A method for manufacturing thin-film natural textured stone reinforced with synthetic resin fibers, characterized in that, Includes the following steps: S1. Raw stone trimming: After the raw stone is mined, it is trimmed into a regular cuboid and polished to obtain natural stone (2) and clamped with a clamp (3); S2, Applying reinforcing fibers: Applying fiber-reinforcing materials to the surface of the cuboid using a resin curing method, allowing the resin to penetrate into the natural stone (2) to reinforce the cracks; S3, Stone cutting: The cuboid with the resin fiber layer already cured is cut into thin stone layers. The cutting trajectory is parallel to the fiber reinforcement material to obtain a thin layer of resin fiber composite natural stone (6). S4. Stone reinforcement: Use an arc mold to bend the resin fiber composite natural stone thin layer (6) to expose the natural stone cracks to facilitate resin penetration. Then flatten the resin fiber composite natural stone thin layer (6) that has been penetrated by resin and squeeze out excess resin. Cure the resin that has penetrated the stone and color the resin.

2. The method for manufacturing synthetic resin fiber reinforced thin natural textured stone as described in claim 1, characterized in that, The surface flatness of the polished surface in step S1 is 0.1~0.2mm.

3. The method for manufacturing thin-film natural textured stone reinforced with synthetic resin fiber as described in claim 1, characterized in that, In step S2, the fiber reinforcement material is a fabric woven from glass fiber, basalt fiber, or carbon fiber.

4. The method for manufacturing thin-film natural textured stone reinforced with synthetic resin fiber as described in claim 1, characterized in that, In step S2, the resin used is acrylic resin, epoxy resin, unsaturated polyester resin or polyurethane resin, and the curing method is determined according to the type of resin used and is at least one of hot air curing, room temperature curing and ultraviolet light curing.

5. The method for manufacturing thin-film natural textured stone reinforced with synthetic resin fiber as described in claim 1, characterized in that, In step S3, the cutting thickness is 3~5mm including grinding allowance.

6. The method for manufacturing thin-film natural textured stone reinforced with synthetic resin fiber as described in claim 1, characterized in that, In step S3, a long cutting tool made of cemented carbide or PCD alloy is used for cutting. The tool is welded to the tool body using copper as a binder and high-frequency heating.

7. The method for manufacturing thin-film natural textured stone reinforced with synthetic resin fiber as described in claim 1, characterized in that, In step S4, the fiber-reinforced material side of the thin-layer stone is bent in a way that it is tightly attached to the arc-shaped mold, so that the cracks of the natural stone are exposed on the reverse side to facilitate resin penetration.

8. The method for manufacturing thin-film natural textured stone reinforced with synthetic resin fiber as described in claim 1, characterized in that, In step S4, the resin that has penetrated the stone is cured by photocuring acrylate resin.

9. The method for manufacturing synthetic resin fiber reinforced thin natural textured stone as described in claim 8, characterized in that, When curing the resin that has penetrated the stone, the resin viscosity is controlled to be 1000 Pa·s, the temperature resistance is above 200℃, the curing agent is 1~5% photoinitiator, and 0.5~2% defoamer is added, and an adhesion promoter is added to the resin.

10. The method for manufacturing thin-film natural textured stone reinforced with synthetic resin fiber as described in claim 1, characterized in that, In step S4, when the resin penetrating the stone is cured, excess resin is reused. After the resin penetrating the stone is cured, it is coarsely ground until the grinding thickness is reached, and then finely ground and polished. Light-cured resin is scraped with a scraper rod and then polished.

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