A large aggregate inorganic artificial stone and a method of making and use thereof

Abstract

A kind of large aggregate inorganic artificial stone and its preparation method and use;Large aggregate inorganic artificial stone, by mass fraction, its raw materials include: 5-60 parts of large aggregate, 5-40 parts of ordinary aggregate, 5-25 parts of 80 mesh calcium sand, 5-25 parts of 90 mesh calcium sand, 5-20 parts of 200-400 mesh calcium powder, 10-30 parts of cement, 0.5-6 parts of mineral admixture, less than 2 parts of stabilizer, less than 3.0 parts of water reducing agent, less than 3.5 parts of modified liquid, less than 2 parts of fiber and 3.0-7.0 parts of water;The particle size of large aggregate is 100-1000mm;The particle size of ordinary aggregate is 4.75-100mm.This scheme realizes full-scale void filling from macro to micro, solves the problem that the density and settlement balance of large aggregate system are difficult to be simultaneously compatible.

Description

Technical Field

[0001] This invention relates to the field of inorganic artificial stone, and more particularly to a large-particle aggregate inorganic artificial stone, its preparation method, and its uses. Background Technology

[0002] Pressed artificial stone is a decorative panel made by mixing aggregates, resins, and additives and then pressing them into shape using vacuum vibration. This process relies on high-frequency vibration and high pressure to achieve a dense bond between the materials. Large aggregate particles are the core of achieving a natural-looking effect in artificial stone. After cutting and polishing, the cross-section of large particles can display the unique crystalline luster, color layers, and rough texture of natural minerals (such as granite, marble mosaic, and terrazzo). The larger the particles, the stronger the three-dimensionality and visual impact of the pattern, breaking away from the "monotonous" fine texture of traditional fine-particle artificial stone and meeting the demand for a grand and natural texture in high-end commercial spaces and personalized home decoration. However, in the current pressing process, large aggregate particles are prone to cracking and displacement. The fundamental reason is that the high-frequency vibration and high pressure during pressing cause the large aggregate particles to shift under vibration conditions, and the larger the particle size, the larger the stress area, making it more susceptible to cracking due to stress concentration. Due to this process limitation, the particle size of large aggregates in conventional pressed artificial stone is usually controlled within the range of 1-15mm. This is mainly because the thickness of conventional finished sheet metal is mostly 20mm, and the aggregate specifications must be smaller than the sheet metal thickness by a certain amount. Otherwise, problems such as the press bursting the aggregate and damaging the mold may occur during pressing, which will seriously affect the product yield and production efficiency.

[0003] However, with the increasing market demand for imitation natural stone textures and large-particle decorative effects, traditional small-diameter aggregates can no longer meet the requirements of high-end decoration. How to solve the problem of density and settlement balance while ensuring the structural integrity and strength of large-particle aggregate slabs has become a technical bottleneck that the artificial stone industry urgently needs to overcome. Summary of the Invention

[0004] The purpose of this invention is to propose an inorganic artificial stone with large aggregate particles, which achieves system optimization through component synergistic design. It adopts a four-level gradation of large aggregate, ordinary aggregate, dual-size calcium sand and ultrafine calcium powder to achieve full-scale void filling from macro to micro.

[0005] To achieve this objective, the present invention adopts the following technical solution: A type of inorganic artificial stone with large aggregate, comprising, by weight, the following raw materials: 5-60 parts of large aggregate, 5-40 parts of ordinary aggregate, 5-25 parts of 80-mesh calcium sand, 5-25 parts of 90-mesh calcium sand, 5-20 parts of 200-400-mesh calcium powder, 10-30 parts of cement, 0.5-6 parts of mineral admixtures, up to 2 parts of stabilizer, up to 3.0 parts of water-reducing agent, up to 3.5 parts of modifying liquid, up to 2 parts of fiber, and 3.0-7.0 parts of water; The large aggregate has a particle size of 100-1000 mm; the ordinary aggregate has a particle size of 4.75-100 mm.

[0006] Optimally, the large aggregate and / or ordinary aggregate is selected from at least one of: crushed stone, quartz sand and calcium carbonate aggregate.

[0007] Optimally, the mineral admixture is one or more combinations of fly ash, silica fume, slag, zeolite powder, metakaolin, and steel slag powder.

[0008] Optimally, the stabilizer is one or more combinations of barium-zinc stabilizers, calcium-zinc stabilizers, rare earth calcium-zinc stabilizers, hydroxyethyl methyl cellulose stabilizers, hydroxyethyl cellulose stabilizers, polyvinyl alcohol stabilizers, calcium chloride stabilizers, sodium chloride stabilizers, polyurea-formaldehyde stabilizers, polyamide stabilizers, Dura fiber stabilizers, and polyacrylate stabilizers.

[0009] Optimally, the fiber is at least one selected from natural plant fibers, chemically synthesized fibers, inorganic non-metallic fibers, and metallic fibers.

[0010] Optimally, the modified liquid is at least one selected from sulfonated naphthaldehyde, nano silica sol, nano silica, nano alumina, organosilicon coupling agent, polyether coupling agent, and polyurethane coupling agent.

[0011] Optimally, the water-reducing agent is a polycarboxylate water-reducing agent.

[0012] A method for preparing inorganic artificial stone with large aggregate particles, used to prepare the above-mentioned inorganic artificial stone with large aggregate particles, includes the following steps: Step (1): Apply epoxy resin backing to the large aggregate and attach the back mesh, then use the back mesh strips to fix them horizontally in series. Step (2): Fix the large aggregates connected in series in the mold, and evenly spread ordinary aggregates with a particle size of 15mm or more around them. Tap the side wall of the mold to vibrate and fill the gaps. Step (3): Mix ordinary aggregates smaller than 15mm with other raw materials, break them evenly into loose materials to make a mixed slurry, and pour it into the mold. Step (4): Cover the upper surface of the mold with an elastic buffer pad, evacuate to -0.1MPa, press under mold vibration, release the vacuum after pressing to obtain inorganic artificial stone blocks; Step (5): After the inorganic artificial stone blocks are left to stand, they are demolded and cured to obtain a large-particle aggregate inorganic artificial stone.

[0013] In step (4), a first elastic buffer pad with a thickness of 0.5 to 2.0 mm and a second elastic buffer pad with a thickness of 0.5 to 4.0 mm are sequentially covered on the upper surface of the mold. The mold is then evacuated to -0.1 MPa and subjected to vibration pressing. The pressure is controlled at 0.1 to 0.5 MPa. After pressing, the vacuum is released to obtain inorganic artificial stone blocks. The vibration suppression parameters are as follows: suppress for at least 10 seconds below 1200Hz; suppress for at least 15 seconds between 1200 and 1600Hz; suppress for at least 20 seconds between 1600 and 1800Hz; and suppress for at least 20 seconds at 1600Hz. The first elastic cushioning pad is a polyvinyl chloride mesh or polyethylene mesh with a mesh size of 3-12 mm; the second elastic cushioning pad is an EVA film, PU film, or TPU film.

[0014] The use of an inorganic artificial stone composition in the preparation of inorganic artificial stone with aggregates larger than 20 mm by a pressing method, wherein the inorganic artificial stone composition comprises, by weight parts: 5-60 parts of large aggregate, 5-40 parts of ordinary aggregate, 5-25 parts of 80-mesh calcium sand, 5-25 parts of 90-mesh calcium sand, 5-20 parts of 200-400-mesh calcium powder, 10-30 parts of cement, 0.5-6 parts of mineral admixtures, up to 2 parts of stabilizer, up to 3.0 parts of water-reducing agent, up to 3.5 parts of modifying liquid, up to 2 parts of fiber, and 3.0-7.0 parts of water; The large aggregate has a particle size of 100-1000 mm; the ordinary aggregate has a particle size of 4.75-100 mm.

[0015] Compared with the prior art, one of the above technical solutions has the following beneficial effects: This solution provides an inorganic artificial stone with large-particle aggregates. Through the optimization of the system achieved by the synergistic design of components, it adopts a four-level distribution of large aggregates, ordinary aggregates, dual-size calcium sand and ultrafine calcium powder to achieve full-scale void filling from macro to micro. This solves the problem that it is difficult to achieve both density and sedimentation balance in the large-particle aggregate system at the same time. Detailed Implementation

[0016] To facilitate understanding of the present invention, a more comprehensive description is provided below. The present invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of the present invention. Where specific techniques or conditions are not specified in the embodiments, they are performed in accordance with techniques or conditions described in the literature in the art or according to product instructions. Reagents or instruments used, unless otherwise specified, are all conventional products that can be obtained commercially.

[0017] A type of inorganic artificial stone with large aggregate, comprising, by weight, the following raw materials: 5-60 parts of large aggregate, 5-40 parts of ordinary aggregate, 5-25 parts of 80-mesh calcium sand, 5-25 parts of 90-mesh calcium sand, 5-20 parts of 200-400-mesh calcium powder, 10-30 parts of cement, 0.5-6 parts of mineral admixtures, up to 2 parts of stabilizer, up to 3.0 parts of water-reducing agent, up to 3.5 parts of modifying liquid, up to 2 parts of fiber, and 3.0-7.0 parts of water; The large aggregate has a particle size of 100-1000 mm; the ordinary aggregate has a particle size of 4.75-100 mm.

[0018] This solution provides an inorganic artificial stone with large-particle aggregates. Through the optimization of the system achieved by the synergistic design of components, it adopts a four-level distribution of large aggregates, ordinary aggregates, dual-size calcium sand and ultrafine calcium powder to achieve full-scale void filling from macro to micro. This solves the problem that it is difficult to achieve both density and sedimentation balance in the large-particle aggregate system at the same time.

[0019] Specifically, large aggregates of 100-1000mm serve as the core of the artificial stone skeleton, providing structural support through particle interlocking, thus enhancing the overall strength and wear resistance of the slab. Simultaneously, the large particle size creates a natural, rugged decorative texture, enhancing visual depth. Reasons for limiting usage: Too low a content results in insufficient skeletal support, leading to slab deformation and lower strength; too high a content reduces particle bulk density, increases porosity, and causes uneven distribution due to gravity settling, resulting in cracking and sand shedding. The 100-1000mm range balances structural stability and adaptability to molding processes. Large aggregates must have a particle size above 100mm to ensure complementary large-to-secondary-to-micro voids with ordinary aggregates (10-50mm) and calcium sand / calcium powder, maximizing full-scale filling advantages and preventing weakening of the skeletal function. Large aggregates must also have a particle size below 1000mm to prevent excessively large gaps between large aggregates, which would prevent secondary aggregates from filling the voids, leading to a loose slab structure and reduced strength. Simultaneously, it considers both decorative and structural performance; aggregates over 100mm can present a natural, rugged texture, matching the needs of exterior walls, landscaping, and other scenarios; those less than 100mm have no difference in decorative properties compared to ordinary stone; aggregates over 100mm are less prone to displacement, ensuring a stable framework; aggregates under 1000mm avoid excessive weight (single piece exceeding 50kg), reducing the risk of settlement, excessive mold pressure, and later cracking. 100-1000mm is suitable for conventional production processes, can be achieved on the fabric, avoiding the problem of too small aggregates being wrapped by fine materials and too large aggregates being difficult to arrange; it also allows for vibration compaction during molding and curing, easy positioning during vacuum molding, and the cementitious material can fully encapsulate the aggregate, preventing exposure or bonding failure.

[0020] Ordinary aggregates are used to fill the voids between large aggregates, optimize aggregate gradation, and improve system density; they also help form a skeletal structure, mitigate the risk of large aggregate settling, and enhance the overall synergy of mechanical properties. The content of ordinary aggregates should be controlled between 5 and 40 parts: if the content is too low, it cannot effectively fill the voids between large aggregates, resulting in insufficient density; if the content is too high, it will suppress the dominant position of the large aggregate skeleton and lead to an imbalance in the proportion of fine aggregates, affecting molding fluidity.

[0021] The content of 80-mesh calcium sand is controlled at 5-25 parts, and the content of 90-mesh calcium sand is controlled at 5-25 parts. The dual-size calcium sand forms a complementary gradation, filling the secondary voids between ordinary and large aggregates, further improving the density of the board. Relying on the high hardness of calcium carbonate, it enhances the surface wear resistance and scratch resistance. If the content of a single type of calcium sand is too low, the filling effect will be insufficient; if the content is too high, it will easily lead to particle agglomeration and destroy the uniformity of the system. The total proportion of the two types of calcium sand is controlled at 10-50 parts to ensure filling efficiency and avoid the risk of shrinkage cracking caused by excessive fine aggregate. Calcium powder of 200-400 mesh, with a content controlled at 5-20 parts, acts as a micro-aggregate to fill the tiny gaps between calcium sands, reducing the porosity of the system. It works synergistically with cementing materials to improve interfacial bonding strength and enhance the surface smoothness of the board. When the content is too low, the micro-filling effect is not obvious, and the density and surface texture of the board are poor. When the content is too high, it will increase the demand for cementing materials, increase production costs, and easily lead to increased water demand due to excessive specific surface area, causing drying shrinkage cracking.

[0022] Cement serves as the core cementing material, generating CSH gel through hydration to firmly bond various aggregates into a cohesive whole, determining the strength and durability of the slab. For example, ordinary Portland cement or high-alumina cement can be used, combining both bonding strength and environmental friendliness. This scheme limits the cement content to 10-30 parts; too low a content results in insufficient cementitious action, ineffective aggregate bonding, and a tendency for sand shedding and delamination; too high a content leads to excessive heat of hydration, concentrated shrinkage stress, and a tendency for internal cracks in the slab, while also increasing production costs and carbon emissions.

[0023] Mineral admixtures can be selected from mineral components such as fly ash, silica fume, and slag powder. These admixtures act as active components, reacting with calcium hydroxide, a cement hydration product, to generate additional gel, strengthening interfacial adhesion. Simultaneously, they act as micro-aggregates to fill voids, improving durability and impermeability. This scheme limits the content of mineral admixtures to 0.5–6 parts. Too low a content results in a weak secondary reaction and insignificant modification; too high a content slows the hydration process, reduces early strength, and may lead to delayed strength development due to insufficient activity. Water provides the medium required for cement hydration, regulates system fluidity, and ensures uniform mixing and dense filling of raw materials during molding. The water content should not be too high or too low. Too low a content results in insufficient hydration and inadequate gel strength; too high a content increases the water-cement ratio, leading to increased drying shrinkage, easy cracking of the board, surface sanding, and reduced density and mechanical properties. Stabilizers, by adjusting the system viscosity, inhibit the sedimentation and agglomeration of large aggregates, ensuring uniform distribution of raw materials during molding; they also enhance the suspension stability of the slurry, preventing stratification. The stabilizer content should be controlled within 2 parts; insufficient stabilizer will lead to inadequate stabilization and failure to inhibit sedimentation; excessive content will result in abnormally increased system viscosity, loss of fluidity, difficulty in molding, and potential residual air bubbles affecting board quality. Water-reducing agents are used to reduce the system's water demand, decreasing the water-cement ratio while maintaining fluidity, thereby improving board strength and density; they also improve the interfacial bonding between aggregates and cementitious materials, reducing porosity. Modifying liquids, which may contain silane coupling agents, nano-silica sols, etc., are used to optimize the interfacial compatibility between aggregates and cementitious materials, improving bond strength; they also improve the board's stain resistance, water resistance, and aging resistance. Fibers are mainly used to form a three-dimensional network structure, dispersing hydration shrinkage stress, inhibiting the generation and propagation of microcracks; improving the board's crack resistance, impact resistance, and toughness, and delaying the risk of early cracking. The stabilizer and fiber form a suspension, providing dual protection against cracking; the modified liquid and mineral admixtures enhance the interface and strength synergistically, breaking through the limitations of single additive modification.

[0024] Optimally, the large aggregate and / or ordinary aggregate is selected from at least one of: crushed stone, quartz sand and calcium carbonate aggregate.

[0025] Large aggregates and ordinary aggregates can be selected from crushed stone, quartz sand, and calcium carbonate aggregates as needed. These raw materials are widely used in skeleton construction and filling. The above-mentioned aggregates are recycled materials. Based on low-cost materials, this solution controls the amount of cement to 10-30 parts, which is lower than the existing extra-coarse aggregate formula (≥30 parts). It does not require high-cost alkali activators in polymer formulas, and can also be compatible with industrial solid waste aggregates, reducing production costs and improving environmental protection. It solves the problem that high performance and low cost cannot be achieved simultaneously in existing technologies.

[0026] Optimally, the mineral admixture is one or more combinations of fly ash, silica fume, slag, zeolite powder, metakaolin, and steel slag powder.

[0027] The mineral admixtures used in this scheme are fly ash, silica fume, slag, zeolite powder, metakaolin, and steel slag powder. Fly ash and slag reduce the heat of hydration; silica fume and metakaolin can improve strength; zeolite powder optimizes workability; the raw materials of the mineral admixtures are mostly industrial solid waste or natural minerals, which are low in cost and have significant emission reduction effects; at the same time, the raw materials of the mineral admixtures have strong compatibility and good synergy with the cement hydration system, without the need for additional formula adjustments.

[0028] Optimally, the stabilizer is one or more combinations of barium-zinc stabilizers, calcium-zinc stabilizers, rare earth calcium-zinc stabilizers, hydroxyethyl methyl cellulose stabilizers, hydroxyethyl cellulose stabilizers, polyvinyl alcohol stabilizers, calcium chloride stabilizers, sodium chloride stabilizers, polyurea-formaldehyde stabilizers, polyamide stabilizers, Dura fiber stabilizers, and polyacrylate stabilizers.

[0029] The stabilizers selected above are mainly based on the formulation system of inorganic artificial stone with large aggregate particles, and are used to specifically improve the performance of inorganic artificial stone with large aggregate particles. For example, calcium-zinc stabilizers and rare earth calcium-zinc stabilizers can be used to adapt to inorganic systems; hydroxyethyl methyl cellulose stabilizers or polyamide stabilizers can be used to inhibit aggregate sedimentation; calcium chloride stabilizers can be used to regulate coagulation. The above stabilizers are safe and stable to use, do not release harmful substances, and are not prone to failure with long-term use; moreover, the amount of stabilizers added is small, the dispersibility is good, and they do not affect the fluidity of the system.

[0030] Optimally, the fiber is at least one selected from natural plant fibers, chemically synthesized fibers, inorganic non-metallic fibers, and metallic fibers.

[0031] Natural plant fibers are generally derived directly from plants in nature and primarily function to retain water, thicken, and prevent surface micro-cracks. Suitable natural plant fibers include wood fibers, hemp fibers, and cotton fibers.

[0032] Chemically synthesized fibers: polypropylene fiber (used to improve crack resistance), polyacrylonitrile fiber (improves light resistance and weather resistance), polyester fiber (improves strength, often used in mortars with high requirements), polyamide fiber (good wear resistance and high toughness), high-strength high-modulus polyethylene fiber (extremely high strength), aromatic polyamide fiber (extremely high strength and high temperature resistance); Inorganic non-metallic fibers are mainly made from the melting and drawing of natural minerals or through special processes. They generally possess characteristics such as non-combustibility, high temperature resistance, high modulus, and crack resistance, and can also significantly improve the impact resistance and flexural strength of concrete. Inorganic fibers that can be selected include alkali-resistant glass fiber, basalt fiber, carbon fiber, and alkali-resistant mineral wool fiber.

[0033] Metal fibers, such as steel fibers, offer the best toughening, impact resistance, and shear resistance among all fibers, and are specifically used in structural concrete that bears enormous loads.

[0034] Optimally, the modified liquid is at least one selected from sulfonated naphthaldehyde, nano silica sol, nano silica, nano alumina, organosilicon coupling agent, polyether coupling agent, and polyurethane coupling agent.

[0035] Modified liquids can be used in combination according to needs to adapt to different performance requirements. They can be used to improve stain resistance, water resistance, and aging resistance, and to make up for the inherent defects of inorganic materials. For example, organosilicon coupling agents and polyurethane coupling agents can be used to improve the bonding between aggregates and cementitious materials. Nano silica sol and nano silica can be used to optimize density.

[0036] Optimally, the water-reducing agent is a polycarboxylate water-reducing agent.

[0037] Polycarboxylate superplasticizers have significant advantages such as high water reduction rate, low dosage, excellent slump retention ability, good cement compatibility, flexible molecular structure design, and green environmental protection, which can comprehensively improve the workability and durability of concrete. Specific examples can be divided into standard type, retarding type, early strength type, viscosity reducing type, and slump-retaining type polycarboxylate superplasticizers according to their functional applications.

[0038] A method for preparing inorganic artificial stone with large aggregate particles, used to prepare the above-mentioned inorganic artificial stone with large aggregate particles, includes the following steps: Step (1): Apply epoxy resin backing to the large aggregate and attach the back mesh, then use the back mesh strips to fix them horizontally in series. Large aggregates (100-1000mm) are backed with a mesh, which can be made of fiberglass mesh and epoxy resin adhesive. The mesh should be 5-10mm larger than the edge of the large aggregates, and 3-5 strips of 2-3mm wide mesh should be used horizontally to connect and fix a row of large aggregates. Ordinary aggregates are distributed near the fixed large aggregates. Applying the mesh prevents large aggregates from breaking due to their own weight or external forces during handling and molding; it increases the contact area between the large aggregates and the cementitious slurry, preventing detachment and improving adhesion; it also buffers hydration shrinkage and stress concentration during use, reducing the risk of cracking and achieving stress dispersion. Epoxy resin adhesive is chosen because it has excellent adhesion and high strength to both the fiberglass mesh and the aggregate surfaces (large and ordinary aggregates); it is also weather-resistant, water-resistant, and anti-aging, ensuring long-term effectiveness; furthermore, epoxy resin has good compatibility with the formulated cementitious system and does not affect the overall performance of the board.

[0039] Step (2): Fix the large aggregates connected in series in the mold, and evenly spread ordinary aggregates with a particle size of 15mm or more around them. Tap the side wall of the mold to vibrate and fill the gaps. Step (3): Mix ordinary aggregates smaller than 15mm with other raw materials, break them evenly into loose materials to make a mixed slurry, and pour it into the mold. Ordinary aggregates smaller than 15mm are mixed with other raw materials (80-mesh calcium sand, 90-mesh calcium sand, 200-400-mesh calcium powder, cement, mineral admixtures, stabilizers, water-reducing agents, modifying liquids, fibers, and water) to form a mixed slurry. This step mainly increases the fluidity of the material slightly, strengthens the connection with the back mesh through the mixed slurry to anchor the large aggregates, and improves the filling fluidity of the mixed slurry, which can improve the bonding force between the cementitious materials and the large aggregates and reduce the risk of cracking of the board.

[0040] Step (4): Cover the upper surface of the mold with an elastic buffer pad, evacuate to -0.1MPa, press under mold vibration, release the vacuum after pressing to obtain inorganic artificial stone blocks; Elastic cushioning pads, made of materials such as rubber, polyurethane, PVC mesh, polyethylene mesh, and EVA film, absorb the instantaneous impact force during pressing, preventing localized stress concentration caused by the press's hard contact with the mold. They disperse the single-point pressing force into a planar force, ensuring even pressure distribution on the sheet surface and reducing the need for localized high pressure. Elastic cushioning pads can also conform to the irregular surfaces of large aggregates, filling gaps between aggregate protrusions and the mold, preventing pressure waste due to insufficient contact and achieving dense molding with less total pressure. Furthermore, because the press head is a steel structure, the elastic cushioning pad reduces the pressure on the stone surface, buffering and absorbing energy to prevent cracking.

[0041] Step (5): After the inorganic artificial stone blocks are left to stand, they are demolded and cured to obtain a large-particle aggregate inorganic artificial stone.

[0042] In step (4), a first elastic buffer pad with a thickness of 0.5 to 2.0 mm and a second elastic buffer pad with a thickness of 0.5 to 4.0 mm are sequentially covered on the upper surface of the mold. The mold is then evacuated to -0.1 MPa and subjected to vibration pressing. The pressure is controlled at 0.1 to 0.5 MPa. After pressing, the vacuum is released to obtain inorganic artificial stone blocks. The vibration suppression parameters are as follows: suppress for at least 10 seconds below 1200Hz; suppress for at least 15 seconds between 1200 and 1600Hz; suppress for at least 20 seconds between 1600 and 1800Hz; and suppress for at least 20 seconds at 1600Hz. The first elastic cushioning pad is a polyvinyl chloride mesh or polyethylene mesh with a mesh size of 3-12 mm; the second elastic cushioning pad is an EVA film, PU film, or TPU film.

[0043] This pressing scheme primarily employs a high-frequency, low-pressure process, with the first elastic buffer pad preferably being a PVC or polyethylene mesh. The main advantage is the mesh structure, which initially disperses the concentrated force from the press head into a planar force, preventing the press head from directly pressing against individual large, protruding aggregates. The 3-12mm aperture provides a channel for gas exhaust during vacuuming, ensuring that air inside the mold can be smoothly extracted without obstructing airflow. Simultaneously, the mesh prevents large aggregates and viscous slurries from tumbling upwards and overflowing during high-frequency vibration, while also allowing fine slurries to slightly float and fill surface pores under vibration. The second elastic buffer pad, located between the press head and the first elastic buffer pad, primarily serves to buffer, seal, and adhere: the second elastic buffer pad absorbs the instantaneous impact force during pressing, achieving "flexible contact" and preventing large aggregates from being crushed due to localized stress concentration. At the same time, the second elastic buffer pad deforms under pressure, perfectly fitting the uneven surface of the large aggregate, filling the gap between the pressure head and the aggregate protrusions, so that the pressure is evenly transmitted to every corner, and can also prevent air leakage, ensuring that the vacuum degree can be successfully achieved and maintained.

[0044] The use of an inorganic artificial stone composition in the preparation of inorganic artificial stone with aggregates larger than 20 mm by a pressing method, wherein the inorganic artificial stone composition comprises, by weight parts: 5-60 parts of large aggregate, 5-40 parts of ordinary aggregate, 5-25 parts of 80-mesh calcium sand, 5-25 parts of 90-mesh calcium sand, 5-20 parts of 200-400-mesh calcium powder, 10-30 parts of cement, 0.5-6 parts of mineral admixtures, up to 2 parts of stabilizer, up to 3.0 parts of water-reducing agent, up to 3.5 parts of modifying liquid, up to 2 parts of fiber, and 3.0-7.0 parts of water; The large aggregate has a particle size of 100-1000 mm; the ordinary aggregate has a particle size of 4.75-100 mm.

[0045] Performance testing: Flexural strength: The flexural strength was determined according to GB / T 50081-2019 "Standard for Test Methods of Physical and Mechanical Properties of Concrete"; Compressive strength: The compressive strength was determined according to GB / T 50081-2019 "Standard for Test Methods of Physical and Mechanical Properties of Concrete"; Density: The density was determined according to GB / T 4111-2013 Test Methods for Concrete Blocks and Bricks.

[0046] Splitting tensile strength: The compressive strength was determined according to GB / T 50081-2019 "Standard for Test Methods of Physical and Mechanical Properties of Concrete".

[0047] Example A: A method for preparing inorganic artificial stone with large aggregate particles includes the following steps: Step (0): Take the raw materials for inorganic artificial stone with granular aggregate. The raw materials include the following by mass: 30 parts of large aggregate, 14 parts of ordinary aggregate, 10 parts of 80-mesh calcium sand, 10 parts of 90-mesh calcium sand, 10 parts of 350-mesh calcium powder, 15 parts of cement, 1 part of mineral admixture, 1 part of stabilizer, 1 part of water-reducing agent, 2 parts of modifying liquid, 1 part of fiber and 5 parts of water. The large and ordinary aggregates are selected from a combination of crushed stone, quartz sand, and calcium carbonate aggregates; the particle size of the large aggregates is 100–1000 mm, with 40% being 100–150 mm and 60% being 150–1000 mm; the particle size of the ordinary aggregates is 4.75–100 mm, with 40% being 4.75–15 mm and 60% being 15–100 mm. The mineral admixtures are a combination of fly ash, silica fume, slag, zeolite powder, metakaolin, and steel slag powder. The stabilizer is a barium-zinc stabilizer. The fiber is basalt fiber. The modifying liquid is a combination of nano-silica sol and organosilicon coupling agent. The water-reducing agent is a commercially available polycarboxylate water-reducing agent.

[0048] Step (1): Apply epoxy resin backing to the large aggregate and attach a backing mesh, then use the backing mesh to fix it horizontally in series; the backing mesh is a fiberglass mesh; the epoxy resin is purchased randomly from the market. Step (2): Fix the large aggregates connected in series in the mold, and evenly spread ordinary aggregates with a particle size of 15mm or more around them. Tap the side wall of the mold to vibrate and fill the gaps. Step (3): Mix ordinary aggregates smaller than 15mm with other raw materials, break them evenly into loose materials to make a mixed slurry, and pour it into the mold. Step (4): Cover the upper surface of the mold with a first elastic buffer pad of 2.0 mm thickness and a second elastic buffer pad of 4.0 mm thickness in sequence, evacuate to -0.1 MPa, and perform vibration pressing. The pressure is controlled at 0.4 MPa. After pressing, release the vacuum to obtain inorganic artificial stone blocks; the first elastic buffer pad is a polyethylene mesh with a mesh aperture of 5-10 mm; the second elastic buffer pad is an EVA film. The vibration suppression parameters are as follows: 10 seconds of suppression at 1200Hz; 15 seconds of suppression at 1600Hz; 20 seconds of suppression at 1800Hz; and 20 seconds of suppression at 1600Hz.

[0049] Step (5): The inorganic artificial stone block is left to stand in the mold for 24 hours. After demolding, it is left to stand at room temperature for another 24 hours. Then it is moved into a constant temperature and humidity environment (room temperature, relative humidity of 90-95%) for curing for 14 days to obtain large-particle aggregate inorganic artificial stone.

[0050] Comparative Example A, which includes Comparative Examples A1-A3.

[0051] Comparative Example A1: The basic steps of Comparative Example A1 are basically the same as those of Example A, except that the particle size of the large aggregate is 100-150 mm and the content is 100%.

[0052] Comparative Example A2: The basic steps of Comparative Example A2 are basically the same as those of Example A, except that ordinary aggregate is not added and step (2) is not performed.

[0053] Comparative Example A3: The basic steps of Comparative Example A3 are basically the same as those of Example A, except that the first elastic buffer pad and the second elastic buffer pad are not set in step (4).

[0054] Performance tests were conducted on Example A and Comparative Examples A1-A3, and the results are shown in Table 1.

[0055] illustrate: 1. Comparing Example A with Comparative Example A1, it can be seen that Comparative Example A1 only has large aggregates with a particle size of 100-150mm, and the large aggregates do not have large particle structures of 150-1000mm. In contrast, this solution provides structural support through the interlocking effect of large particles. The back mesh can increase the contact area between the large particle structures of 150-1000mm in the large aggregates and the cementitious slurry. Ordinary aggregates are made into a fluid mixed slurry to fill between the large particle structures, thereby improving the strength of the board (flexural strength, compressive strength and splitting tensile strength). Obviously, Comparative Example A1 did not introduce large aggregates with large particle sizes. Under similar density conditions, the flexural strength (7MPa), compressive strength (30MPa) and splitting tensile strength (3.1MPa) of Comparative Example A1 are lower than those of Example A (10MPa), compressive strength (60MPa) and splitting tensile strength (3.8MPa), respectively.

[0056] 2. Comparing Example A and Comparative Example A2, it can be seen that Comparative Example A2 does not add ordinary aggregate, while the ordinary aggregate in this solution is used to fill the voids between large aggregates, optimize the aggregate gradation, improve the system density, assist in forming a skeleton structure, alleviate the risk of large aggregate settlement, and enhance the overall mechanical property synergy. Obviously, the lack of ordinary aggregate will lead to the inability to effectively fill the voids between large aggregates in Comparative Example A2, which will reduce both the density and strength (flexural strength, compressive strength, and splitting tensile strength) of Comparative Example A2. The density of Comparative Example A2 decreased from 2600 kg / m³ in Example A to 2000 kg / m³. The flexural strength (5 MPa), compressive strength (25 MPa), and splitting tensile strength (2.9 MPa) of Comparative Example A2 are lower than those of Example A (10 MPa), (60 MPa), and (3.8 MPa), respectively.

[0057] 3. As can be seen from the comparison between Example A and Comparative Example A3, Comparative Example A3 does not have the first elastic buffer pad and the second elastic buffer pad provided in Example A; while the elastic buffer pad of this solution can fit the irregular surface of the large aggregate, fill the gap between the aggregate protrusion and the mold, reduce the pressure on the stone surface, and buffer and absorb energy to prevent the stone from cracking. Because inorganic artificial stone blocks contain large aggregates of 150-1000mm, the skeleton strength of the artificial stone is low when it is not formed. In contrast, Comparative Example A3 damaged the structure of some large aggregates during the vibration pressing process, and some large aggregates cracked. This caused the system formed by the four-level gradation of large aggregates, ordinary aggregates, dual-size calcium sand and ultrafine calcium powder to fail locally, which in turn reduced the skeleton support of the stone. Therefore, the flexural strength (7MPa), compressive strength (42MPa) and splitting tensile strength (3.3MPa) of Comparative Example A3 are lower than those of Example A (10MPa), compressive strength (60MPa) and splitting tensile strength (3.8MPa), respectively.

[0058] In summary, this scheme achieves system optimization through component synergistic design, using a four-stage gradation of large aggregates, ordinary aggregates, dual-size calcium sand, and ultrafine calcium powder to achieve full-scale void filling from macro to micro, thus solving the problem of simultaneously achieving both density and sedimentation balance in large-particle aggregate systems.

[0059] Example B: A method for preparing inorganic artificial stone with large aggregate particles includes the following steps: Step (0): Take the raw materials for the inorganic artificial stone with granular aggregate. The raw materials include the following by mass: 6 parts of large aggregate, 30 parts of ordinary aggregate, 10 parts of 80-mesh calcium sand, 10 parts of 90-mesh calcium sand, 15 parts of 200-400-mesh calcium powder, 15 parts of cement, 5 parts of mineral admixture, 0.5 parts of stabilizer, 0.5 parts of water-reducing agent, 0.5 parts of modifying liquid, 0.5 parts of fiber and 7 parts of water. Large aggregates and / or ordinary aggregates are selected from a combination of crushed stone and calcium carbonate aggregates; the particle size of the large aggregates is 100–1000 mm, with 30% being 100–150 mm and 70% being 150–1000 mm; the particle size of the ordinary aggregates is 4.75–100 mm, with 30% being 4.75–15 mm and 70% being 15–100 mm. The aggregates are a combination of quartz sand and calcium carbonate aggregates. The mineral admixtures are a combination of fly ash, silica fume, slag, and zeolite powder. The stabilizer is a combination of barium-zinc and calcium-zinc stabilizers. The fibers are wood fibers and polypropylene fibers. The modifying liquid is an organosilicon coupling agent. The water-reducing agent is a commercially available polycarboxylate water-reducing agent.

[0060] Step (1): Apply epoxy resin backing to the large aggregate and attach the backing mesh, then use backing mesh strips to fix it horizontally in series; the backing mesh is fiberglass mesh; the epoxy resin is purchased randomly from the market. Step (2): Fix the large aggregates connected in series in the mold, and evenly spread ordinary aggregates with a particle size of 15mm or more around them. Tap the side wall of the mold to vibrate and fill the gaps. Step (3): Mix ordinary aggregates smaller than 15mm with other raw materials, break them evenly into loose materials to make a mixed slurry, and pour it into the mold. Step (4): Cover the upper surface of the mold with a 1mm thick first elastic buffer pad and a 2mm thick second elastic buffer pad in sequence, evacuate to -0.1MPa, and perform vibration pressing. The pressure is controlled at 0.5MPa. After pressing, release the vacuum to obtain inorganic artificial stone blocks; the first elastic buffer pad is a polyethylene mesh with a mesh aperture of 3-5mm; the second elastic buffer pad is a PU film. The vibration suppression parameters are as follows: 10 seconds of suppression at 1200Hz; 15 seconds of suppression at 1600Hz; 20 seconds of suppression at 1800Hz; and 20 seconds of suppression at 1600Hz.

[0061] Step (5): The inorganic artificial stone block is left to stand in the mold for 48 hours. After demolding, it is left to stand at room temperature for another 48 hours. Then it is moved to a constant temperature and humidity environment (room temperature, relative humidity of 90-95%) for curing for 10 days to obtain large-particle aggregate inorganic artificial stone.

[0062] Example C: A method for preparing inorganic artificial stone with large aggregate particles includes the following steps: Step (0): Take the raw materials for inorganic artificial stone with granular aggregate. The raw materials include the following by mass: 60 parts of large aggregate, 5 parts of ordinary aggregate, 5 parts of 80-mesh calcium sand, 5 parts of 90-mesh calcium sand, 5 parts of 200-400-mesh calcium powder, 10 parts of cement, 6 parts of mineral admixture, 0.2 parts of stabilizer, 0.2 parts of water-reducing agent, 0.2 parts of modifying liquid, 0.4 parts of fiber and 3 parts of water; Large aggregates and / or ordinary aggregates are selected from a combination of crushed stone and quartz sand. The particle size of the large aggregates is 100–1000 mm, with 50% being 100–150 mm and 50% being 150–1000 mm; the particle size of the ordinary aggregates is 4.75–100 mm, with 50% being 4.75–15 mm and 50% being 15–100 mm. The mineral admixtures are a combination of fly ash, silica fume, slag, and zeolite powder. The stabilizer is a combination of barium-zinc and calcium-zinc stabilizers. The fibers are wood fibers and polypropylene fibers. The modifying liquid is an organosilicon coupling agent. The water-reducing agent is a commercially available polycarboxylate superplasticizer.

[0063] Step (1): Apply epoxy resin backing to the large aggregate and attach the backing mesh, then use backing mesh strips to fix it horizontally in series; the backing mesh is fiberglass mesh; the epoxy resin is purchased randomly from the market. Step (2): Fix the large aggregates connected in series in the mold, and evenly spread ordinary aggregates with a particle size of 15mm or more around them. Tap the side wall of the mold to vibrate and fill the gaps. Step (3): Mix ordinary aggregates smaller than 15mm with other raw materials, break them evenly into loose materials to make a mixed slurry, and pour it into the mold. Step (4): Cover the upper surface of the mold with a 2mm thick first elastic buffer pad and a 3mm thick second elastic buffer pad in sequence, evacuate to -0.1MPa, and perform vibration pressing. The pressure is controlled at 0.3MPa. After pressing, release the vacuum to obtain inorganic artificial stone blocks; the first elastic buffer pad is a polyvinyl chloride mesh with a mesh aperture of 5-8mm; the second elastic buffer pad is a rubber pad. The vibration suppression parameters are as follows: 12 seconds of suppression at 1200Hz; 20 seconds of suppression at 1600Hz; 22 seconds of suppression at 1800Hz; and 22 seconds of suppression at 1600Hz.

[0064] Step (5): The inorganic artificial stone block is left to stand in the mold for 24 hours. After demolding, it is left to stand at room temperature for another 24 hours. Then, it is moved into a constant temperature and humidity environment (room temperature, relative humidity of 90-95%) for curing for 10 days to obtain large-particle aggregate inorganic artificial stone.

[0065] Performance tests were conducted on Examples B and C, and the results are shown in Table 2.

[0066] Table 2 - Performance test results of Examples B and C

[0067] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A type of inorganic artificial stone using large-particle aggregate, characterized in that, By weight, its raw materials include: 5-60 parts of large aggregate, 5-40 parts of ordinary aggregate, 5-25 parts of 80-mesh calcium sand, 5-25 parts of 90-mesh calcium sand, 5-20 parts of 200-400-mesh calcium powder, 10-30 parts of cement, 0.5-6 parts of mineral admixtures, up to 2 parts of stabilizer, up to 3.0 parts of water-reducing agent, up to 3.5 parts of modifying liquid, up to 2 parts of fiber, and 3.0-7.0 parts of water; The large aggregate has a particle size of 100-1000 mm; the ordinary aggregate has a particle size of 4.75-100 mm.

2. The inorganic artificial stone with large aggregate as described in claim 1, characterized in that, The large aggregate and / or ordinary aggregate are selected from at least one of the following: crushed stone, quartz sand and calcium carbonate aggregate.

3. The inorganic artificial stone with large aggregate as described in claim 1, characterized in that, The mineral admixture is one or more of the following: fly ash, silica fume, slag, zeolite powder, metakaolin, and steel slag powder.

4. The inorganic artificial stone with large aggregate as described in claim 1, characterized in that, The stabilizer is one or more combinations of barium zinc stabilizer, calcium zinc stabilizer, rare earth calcium zinc stabilizer, hydroxyethyl methyl cellulose stabilizer, hydroxyethyl cellulose stabilizer, polyvinyl alcohol stabilizer, calcium chloride stabilizer, sodium chloride stabilizer, polyurea formaldehyde stabilizer, polyamide stabilizer, Dura fiber stabilizer, and polyacrylate stabilizer.

5. The inorganic artificial stone with large aggregate as described in claim 1, characterized in that, The fiber is at least one of natural plant fiber, chemically synthesized fiber, inorganic non-metallic fiber, and metallic fiber.

6. The inorganic artificial stone with large aggregate as described in claim 1, characterized in that, The modified liquid is at least one of sulfonated naphthaldehyde, nano silica sol, nano silica, nano alumina, organosilicon coupling agent, polyether coupling agent, and polyurethane coupling agent.

7. The inorganic artificial stone with large aggregate as described in claim 1, characterized in that, The water-reducing agent is a polycarboxylate water-reducing agent.

8. A method for preparing inorganic artificial stone with large aggregate particles, used to prepare the inorganic artificial stone with large aggregate particles as described in any one of claims 1-7, characterized in that, Includes the following steps: Step (1): Apply epoxy resin backing to the large aggregate and attach the back mesh, then use the back mesh strips to fix them horizontally in series. Step (2): Fix the large aggregates in series in the mold, and evenly spread ordinary aggregates with a particle size of 15mm or more around them. Tap the side wall of the mold to vibrate and fill the gaps. Step (3): Mix ordinary aggregates smaller than 15mm with other raw materials, break them evenly into loose materials to make a mixed slurry, and pour it into the mold. Step (4): Cover the upper surface of the mold with an elastic buffer pad, evacuate to -0.1MPa, press under mold vibration, release the vacuum after pressing to obtain inorganic artificial stone blocks; Step (5): After the inorganic artificial stone blocks are left to stand, they are demolded and cured to obtain a large-particle aggregate inorganic artificial stone.

9. The method for preparing inorganic artificial stone with large aggregate particles according to claim 8, characterized in that, In step (4), a first elastic buffer pad with a thickness of 0.5 to 2.0 mm and a second elastic buffer pad with a thickness of 0.5 to 4.0 mm are sequentially covered on the upper surface of the mold. The vacuum is drawn to -0.1 MPa and vibration pressing is performed. The pressure is controlled at 0.1 to 0.5 MPa. After pressing, the vacuum is released to obtain inorganic artificial stone blocks. The vibration suppression parameters are as follows: suppress for at least 10 seconds below 1200Hz; suppress for at least 15 seconds between 1200 and 1600Hz; suppress for at least 20 seconds between 1600 and 1800Hz; and suppress for at least 20 seconds at 1600Hz. The first elastic cushioning pad is a polyvinyl chloride mesh or polyethylene mesh with a mesh size of 3-12 mm; the second elastic cushioning pad is an EVA film, PU film, or TPU film.

10. The use of an inorganic artificial stone composition in the preparation of inorganic artificial stone with aggregates having a particle size greater than 20 mm by a pressing method, characterized in that, The inorganic artificial stone composition comprises, by weight parts: 5-60 parts of large aggregate, 5-40 parts of ordinary aggregate, 5-25 parts of 80-mesh calcium sand, 5-25 parts of 90-mesh calcium sand, 5-20 parts of 200-400-mesh calcium powder, 10-30 parts of cement, 0.5-6 parts of mineral admixtures, up to 2 parts of stabilizer, up to 3.0 parts of water-reducing agent, up to 3.5 parts of modifying liquid, up to 2 parts of fiber, and 3.0-7.0 parts of water; The large aggregate has a particle size of 100-1000 mm; the ordinary aggregate has a particle size of 4.75-100 mm.

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