Organic Fiber Toughened Inorganic Composite Stone Panel
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Solution Overview
Problem
Traditional artificial stone panels face issues such as large thermal deformation, low compressive strength, high water absorption, brittleness, and short service life, which limit their performance and safety for infrastructure applications.
Innovation Solution
An organic fiber toughened inorganic composite artificial stone panel with a multilayer structure comprising a surface layer, intermediate organic fiber toughened layer, and toughened base layer, utilizing specific materials and manufacturing processes to enhance strength, durability, and resistance to deformation and staining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional cement-based terrazzo-type inorganic artificial stone is used, then the panel has low cost and simple structure, but it exhibits low compressive strength, poor hardness, low bending strength, high brittleness, and high water absorption
Solution Approach 1:
The patent uses composite materials by combining inorganic active powder (cement, lime, fly ash) with organic fibers (polypropylene, polyester, or polyacrylic fibers) to create a hybrid composite artificial stone panel. This composite structure provides both the strength and durability of inorganic materials and the toughness and crack resistance of organic fibers, resolving the contradiction between strength and structural simplicity.
2Strength
If metal mesh or fiber mesh reinforcement structure is added to improve tensile strength, then crack development is slowed down, but the brittle surface still bends and deforms under pressure causing brittle fracture
Solution Approach 1:
The patent applies local quality by distributing organic fibers uniformly throughout the entire panel matrix rather than concentrating reinforcement only in a mesh structure. This ensures that tensile strength is provided throughout the material, and when cracking occurs, the fibers locally bridge cracks and prevent brittle fracture propagation, maintaining reliability under pressure.
3Strength
If fiber base layer is introduced to overcome deformation and cracking, then surface fiber exposure and fiber channel opening occur during bottom scraping, causing increased water absorption and corrosion damage
Solution Approach 1:
The patent extracts the fiber reinforcement function from a separate base layer and integrates it uniformly throughout the entire panel matrix. This eliminates the need for a distinct fiber base layer that would be exposed during scraping, thereby preventing fiber channel opening and the associated water absorption and corrosion problems while maintaining toughness and crack resistance.
4Ease of manufacture
If resin-type organic artificial stone is used, then the panel has good workability and can replace natural stone, but it exhibits large thermal deformation, easy expansion and cracking, aging deformation, discoloration, and short service life
Solution Approach 1:
The patent creates a composite material system where inorganic active powder provides thermal stability, dimensional stability, and long-term durability, while organic fibers provide toughness and crack resistance. This composite approach maintains the workability needed for manufacturing while eliminating the thermal deformation, aging deformation, and short service life problems of pure resin-type organic artificial stone.
Data Source
Figure 1
AI summary
An organic fiber toughened inorganic composite artificial stone panel and a preparation method thereof are disclosed. The panel includes a surface layer, an intermediate organic fiber toughened layer and a toughened base layer. The surface layer includes the following components: 40-70 parts of quartz sand, 20-30 parts of quartz powder, 20-45 parts of inorganic active powder, 0.5-4 parts of pigment, 0.1-3 part of water reducing agent and 3-10 parts of water. The intermediate organic fiber toughened layer includes the following components: 40-60 parts of inorganic active powder, 45-65 parts of sand, 0.8-1.5 parts of water reducing agent, 6-14 parts of water and 4-8 parts of organic fiber. The toughened base layer includes the following components: 30-50 parts of inorganic active powder, 30-55 parts of quartz sand, 15-20 parts of quartz powder, 0.5-1.2 parts of water reducing agent, 4-8 parts of water and 0.8-2.5 parts of toughener.