Compound additive for quartz stone plate roll extrusion forming and forming process

Abstract

The application provides a compound additive for quartz stone plate roll extrusion forming and a forming process, the compound additive comprises internal lubricating components and external lubricating anti-sticking components in a mass ratio of 2.5-4:1, the internal lubricating components are stearate lubricating materials, and the external lubricating anti-sticking components are oxyalkylene wax lubricating materials. The forming process comprises the following steps, S1. raw material preparation: according to a conventional formula of the quartz stone plate, quartz aggregate, quartz powder, unsaturated polyester resin, coupling agent, curing agent and colorant are weighed, and the compound additive is weighed at the same time, the addition amount of the compound additive is 0.6-2.2% of the total mass of the formula; S2. stirring and mixing; S3. roll extrusion forming; and S4. curing post-treatment. The compound additive for quartz stone plate roll extrusion forming and the forming process can solve the contradiction between the flowability of the mixed material and the roll sticking in the industry for a long time, and can help the plate product to form differentiated competitiveness in the high-end decoration market through the improvement of the texture definition.

Description

Technical Field

[0001] This invention relates to the field of building materials processing technology, specifically to a compound additive and molding process for roller extrusion molding of quartz stone slabs. Background Technology

[0002] Quartz stone slabs have become the mainstream artificial stone product in the field of building decoration due to their wear resistance, corrosion resistance, and beautiful texture. Roller extrusion molding is the core process for the continuous production of quartz stone slabs. This process achieves rapid compaction and molding of slabs through double roller extrusion, and the production efficiency is far higher than that of traditional molding process.

[0003] Currently, the existing quartz stone roll extrusion production process suffers from two major long-standing technical bottlenecks that severely restrict product quality and production efficiency:

[0004] Firstly, the quartz stone mixture has poor internal fluidity. The mixture is composed of quartz aggregate, quartz powder, resin and conventional auxiliary materials. The interfacial friction between the components is large, and smooth internal flow cannot be achieved during the extrusion process. This results in stiff and rigid texture formation when the slab is formed, and it cannot form a natural and smooth imitation natural texture effect. In addition, the density of the mixture is uneven, and the product defect rate remains high.

[0005] Secondly, the problem of resin sticking to the rollers during the extrusion process is serious. Existing manufacturers generally use the method of laying an anti-stick film on the roller surface to improve the sticking problem. However, the film cannot fundamentally solve the problem of resin adhesion to the roller. Local adhesion will still occur during the extrusion process, resulting in poor extensibility of the mixture and broken texture of the board. This not only affects the appearance of the finished product, but also requires frequent shutdowns to clean the rollers, which greatly reduces production efficiency and further increases the production defect rate. Summary of the Invention

[0006] To overcome the shortcomings of existing technologies, this invention provides a compound additive and molding process for roller extrusion molding of quartz stone slabs. This not only solves the long-standing contradiction between the fluidity of the mixture and the sticking to the rollers in the industry, but also helps the slab products form a differentiated competitive advantage in the high-end decoration market by improving the clarity of the texture.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0008] A compound additive for roller extrusion molding of quartz stone slabs includes an internal lubricating component and an external lubricating and anti-sticking component in a mass ratio of 2.5 to 4:1. The internal lubricating component is a stearate ester lubricating material, and the external lubricating and anti-sticking component is an olefinic wax lubricating material.

[0009] The internal lubricating component acts quickly inside the quartz stone mixture, reducing the interfacial friction between the resin and the quartz powder and aggregate, and greatly improving the internal fluidity of the mixture. This allows the mixture to flow and stratify naturally under extrusion pressure, forming a smooth, natural, and imitation natural texture without external intervention, thus eliminating the problem of stiff and rigid textures.

[0010] The external lubricating and anti-sticking components form a stable isolation layer at the interface between the roller and the mixture. Without the need for additional anti-sticking film, the mixture can be completely prevented from adhering to the roller, ensuring smooth extrusion of the mixture during extrusion, without adhesion or texture breaks, and resulting in a high degree of integrity in the appearance of the formed sheet.

[0011] Furthermore, stearate lubricants include one of glyceryl monostearate, n-butyl stearate, isooctyl stearate, pentaerythritol tetrastearate, lauryl stearate, ethylene glycol distearate, and triethylene glycol distearate; oxidized olefin wax lubricants include one of oxidized polyethylene wax and oxidized polypropylene wax.

[0012] The present invention also provides a process for roller extrusion molding of quartz stone slabs, wherein the above-mentioned compound additives are added to the conventional formula of quartz stone slabs, and the amount of compound additives added is 0.6 to 2.2% of the total mass of the formula.

[0013] Furthermore, the process includes the following steps:

[0014] S1. Raw material preparation: Weigh out quartz aggregate, quartz powder, unsaturated polyester resin, coupling agent, curing agent, and colorant according to the conventional formula of quartz stone slabs, and weigh out the compound additives at the same time.

[0015] S2. Mixing: Add quartz aggregate and quartz powder into the mixing equipment, first dry mix and disperse for 3-6 minutes, then add unsaturated polyester resin, coupling agent and colorant, continue mixing for 8-15 minutes, and finally add compounding additives and curing agent, and mix at low speed for 5-10 minutes.

[0016] S3. Roller extrusion molding: The mixture from step S2 is fed into the feed inlet of the roller extruder, and the parameters of the roller extruder are adjusted.

[0017] S4. Post-curing treatment: The formed quartz stone blank is sent into the curing equipment for constant temperature curing treatment.

[0018] Furthermore, in step S3, the roller linear speed is 0.7 to 1.6 m / min, and the inter-roller extrusion pressure is 7 to 16 MPa.

[0019] Furthermore, in step S4, the curing temperature is 85–1125℃ and the curing time is 25–160 min.

[0020] Compared with the prior art, the present invention has the following beneficial technical effects:

[0021] (1) The compound additive of the present invention has an internal lubricating component that targets the internal system of the quartz stone mixture, which can effectively reduce the frictional resistance between each solid particle and the resin, eliminate the problem of mixture agglomeration and poor flow, and allow the mixture to have sufficient internal flow space during extrusion, naturally forming a smooth texture; the external lubricating component targets the roller contact interface, forming a dual function of physical isolation and lubrication, replacing the traditional anti-stick film, eliminating the phenomenon of sticking to the roller from the root, ensuring the continuous and stable extrusion process, and the two components do not interfere with each other and work synergistically to achieve the dual technical effects of internal flow and external anti-stick.

[0022] (2) The quartz stone slab roller extrusion molding process of the present invention abandons the inefficient anti-sticking method of traditional anti-stick film, and completely solves the problem of roller sticking during roller extrusion by compounding additive modification. There is no sticking, no poor extension, and no texture breakage during the extrusion process. There is no need to frequently stop the machine to clean the rollers, and the production efficiency is greatly improved.

[0023] (3) The quartz stone slab roll extrusion molding process of the present invention improves the internal fluidity of the mixture, so that the slab has a natural and smooth texture and a strong sense of layering, which is completely different from the rigid and stiff texture of existing products. The appearance and texture of the slab are closer to natural stone, and the product competitiveness is significantly improved.

[0024] (4) The quartz stone slab roll extrusion molding process of the present invention has uniform density of the mixture, no molding defects, no texture breaks, and the finished product appearance and performance compliance rate is greatly improved, effectively reducing production losses and improving production efficiency.

[0025] (5) The quartz stone slab double roll extrusion molding process of the present invention does not require modification of the existing double roll extrusion production equipment. It only requires adding the compound additive of the present invention in the mixing stage. The process is simple to operate, suitable for large-scale continuous production, and easy to promote and apply. Detailed Implementation

[0026] Numerous specific details are set forth in the following description to provide a full understanding of the invention. However, the invention can be practiced in many other ways than those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0027] Example 1

[0028] A compound additive for roller extrusion molding of quartz stone slabs comprises an internal lubricant and an external lubricant / anti-sticking component in a mass ratio of 3:1. The internal lubricant is a stearate-based lubricant, including one of glyceryl monostearate, n-butyl stearate, isooctyl stearate, pentaerythritol tetrastearate, lauryl stearate, ethylene glycol distearate, and triethylene glycol distearate. The external lubricant / anti-sticking component is an oxidized olefin wax lubricant, including one of oxidized polyethylene wax and oxidized polypropylene wax.

[0029] A roll extrusion molding process for quartz stone slabs includes the following steps:

[0030] S1. Raw material preparation: Weigh out 65 parts of quartz aggregate, 22 parts of quartz powder, 9 parts of unsaturated polyester resin, 0.5 parts of silane coupling agent, 0.3 parts of curing agent, 1 part of colorant, and 1.2 parts of compounding additives by weight.

[0031] S2. Mixing: Add quartz aggregate and quartz powder to the mixer and dry mix for 5 minutes. Add resin, coupling agent and colorant and mix for 12 minutes. Finally, add compounding additives and curing agent and mix for 8 minutes to obtain a well mixed material.

[0032] S3. Roller extrusion molding: The mixture is fed into the feed port of the roller extruder, and the parameters of the roller extruder are adjusted to 1.0 m / min for roller linear speed and 11 MPa for inter-roller pressure, and continuous extrusion molding is performed.

[0033] S4. Post-curing treatment: The formed quartz stone blank is sent into the curing equipment and cured at a constant temperature of 100℃ for 45 minutes. After that, it is polished and cut to obtain the finished slab.

[0034] Example 2

[0035] A compound additive for roller extrusion molding of quartz stone slabs comprises an internal lubricant and an external lubricant / anti-sticking component in a mass ratio of 3.5:1. The internal lubricant is a stearate-based lubricant, including one of glyceryl monostearate, n-butyl stearate, isooctyl stearate, pentaerythritol tetrastearate, lauryl stearate, ethylene glycol distearate, and triethylene glycol distearate. The external lubricant / anti-sticking component is an oxidized olefin wax lubricant, including one of oxidized polyethylene wax and oxidized polypropylene wax.

[0036] A roll extrusion molding process for quartz stone slabs includes the following steps:

[0037] S1. Raw material preparation: Weigh out 72 parts of quartz aggregate, 18 parts of quartz powder, 7.5 parts of unsaturated polyester resin, 0.4 parts of silane coupling agent, 0.25 parts of curing agent, 0.8 parts of colorant, and 1.5 parts of compounding additives by weight.

[0038] S2. Mixing: Add quartz aggregate and quartz powder to the mixer and dry mix for 4 minutes. Add resin, coupling agent and colorant and mix for 10 minutes. Finally, add compounding additives and curing agent and mix for 7 minutes to obtain a well mixed material.

[0039] S3. Roller extrusion molding: The mixture is fed into the feed port of the roller extruder. The parameters of the roller extruder are adjusted, with the roller linear speed at 1.2 m / min and the inter-roller pressure at 13 MPa, and continuous extrusion molding is performed.

[0040] S4. Post-curing treatment: The formed quartz stone blank is sent into the curing equipment and cured at a constant temperature of 95℃ for 50 minutes. After that, it is polished and cut to obtain the finished slab.

[0041] Effect test

[0042] The performance and production efficiency of the boards prepared in Examples 1 and 2 of this invention were compared with those produced by conventional processes using anti-stick film and without compounding additives. The results are shown in the table below:

[0043] Test metrics Example 1 Example 2 conventional process Internal fluidity of the mixture Excellent, smooth flow Excellent, smooth flow Poor flow Roller sticking No sticking to the rollers No sticking to the rollers Localized roller sticking requires frequent cleaning. Board texture effect Smooth and natural, mimicking natural texture Smooth and natural, mimicking natural texture Rigid and inflexible, prone to faulting Product manufacturing pass rate 98.2% 98.5% 82.3% Production efficiency Continuous production, no downtime for cleaning Continuous production, no downtime for cleaning Frequent downtime and low efficiency

[0044] Production test results show that, by adding exclusive compound additives and combining them with an optimized roller extrusion process, this invention is far superior to existing conventional production processes in terms of flowability, anti-sticking effect, product qualification rate, production efficiency, and sheet appearance, completely solving the existing technical pain points in the industry.

[0045] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. However, any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A compound additive for roller extrusion molding of quartz stone slabs, characterized in that: It includes an internal lubricating component and an external lubricating and anti-sticking component in a mass ratio of 2.5 to 4:

1. The internal lubricating component is a stearate ester lubricating material, and the external lubricating and anti-sticking component is an olefinic wax lubricating material.

2. The compound additive for roller extrusion molding of quartz stone slabs according to claim 1, characterized in that: Stearate lubricants include one of the following: glyceryl monostearate, n-butyl stearate, isooctyl stearate, pentaerythritol tetrastearate, lauryl stearate, ethylene glycol distearate, and triethylene glycol distearate. Oxidized olefin wax lubricants include one of the following: oxidized polyethylene wax and oxidized polypropylene wax.

3. A process for roller extrusion molding of quartz stone slabs, characterized in that: The conventional formulation of quartz stone slabs contains the compound additives described in claim 1 or 2, wherein the amount of the compound additives added is 0.6 to 2.2% of the total mass of the formulation.

4. The quartz stone slab roll extrusion molding process according to claim 3, characterized in that, Includes the following steps: S1. Raw material preparation: Weigh out quartz aggregate, quartz powder, unsaturated polyester resin, coupling agent, curing agent, and colorant according to the conventional formula of quartz stone slabs, and weigh out the compound additives at the same time. S2. Mixing: Add quartz aggregate and quartz powder into the mixing equipment, first dry mix and disperse for 3-6 minutes, then add unsaturated polyester resin, coupling agent and colorant, continue mixing for 8-15 minutes, and finally add compounding additives and curing agent, and mix at low speed for 5-10 minutes. S3. Roller extrusion molding: The mixture from step S2 is fed into the feed inlet of the roller extruder, and the parameters of the roller extruder are adjusted. S4. Post-curing treatment: The formed quartz stone blank is sent into the curing equipment for constant temperature curing treatment.

5. The quartz stone slab roll extrusion molding process according to claim 4, characterized in that: In step S3, the roller linear speed is 0.7 to 1.6 m / min, and the inter-roller extrusion pressure is 7 to 16 MPa.

6. The quartz stone slab roll extrusion molding process according to claim 5, characterized in that: In step S4, the curing temperature is 85–1125℃ and the curing time is 25–160 min.