阅读说明：本技术 一种低成本工业合成石加工工艺 (Low-cost industrial synthetic stone processing technology ) 是由 王坤 刘杰 于 2020-12-04 设计创作，主要内容包括：本发明提供了一种低成本工业合成石加工工艺,包括如下步骤：(1)将天然石骨料、填充物、粘合剂混合,形成混合料；(2)将混合料按照所需厚度平整的布置在模框内,在混合料的底面和顶面分别设置有脱模层；(3)将混合料进行真空排气后送入成型设备中压制,对物料进行分区振动,每个分区需要一个振动单元,在振动单元与混合料之间设置有一模板,所有振动单元分区振动在所述模板上,振动单元的振动力为40N～120N/cm～2；(4)对成型的混合料进行固化,得到成品。本发明方法大大减少了树脂的使用量,且得到的板材致密度、硬度高,防渗透性好,极大地降低了生产成本。(The invention provides a low-cost industrial synthetic stone processing technology, which comprises the following steps: (1) mixing natural stone aggregate, filler and adhesive to form a mixture; (2) the mixture is flatly arranged in a die frame according to the required thickness, and the bottom surface and the top surface of the mixture are respectively provided with a demoulding layer; (3) the method comprises the steps of carrying out vacuum exhaust on a mixture, then conveying the mixture into a forming device for pressing, carrying out partition vibration on the material, wherein each partition needs a vibration unit, a template is arranged between each vibration unit and the mixture, all the vibration units vibrate on the template in a partition mode, and the vibration force of each vibration unit is 40-120N/cm 2 (ii) a (4) And curing the formed mixture to obtain a finished product. The method greatly reduces the using amount of resin, and the obtained plate has high density, hardness and permeability resistance, thereby greatly reducing the production cost.)

1. A low-cost industrial synthetic stone processing technology is characterized by comprising the following steps:

(1) mixing natural stone aggregate, filler and adhesive to form a mixture;

(2) the mixture is flatly arranged in a die frame according to the required thickness, and the bottom surface and the top surface of the mixture are respectively provided with a demoulding layer;

(3) the method comprises the steps of carrying out vacuum exhaust on a mixture, then conveying the mixture into a forming device for pressing, carrying out partition vibration on the material, wherein each partition needs a vibration unit, a template is arranged between each vibration unit and the mixture, all the vibration units vibrate on the template in a partition mode, and the vibration force of each vibration unit is 40-120N/cm²；

(4) And curing the formed mixture to obtain a finished product.

2. The process according to claim 1, wherein the filler is selected from the group consisting of construction-based solid waste, industrially produced powder-based residue, cement, sand and soil.

3. The processing technology of claim 2, wherein the building solid waste comprises waste wood boards, waste plastic boards, waste ceramic granules, waste polyphenyl granule boards and waste metals.

4. The process of claim 2, wherein the industrially produced powdered residue comprises industrially produced fly ash, coal ash or fly ash.

5. The process of claim 1, wherein the adhesive comprises one or more of epoxy resin, starch, polystyrene, polyacrylate, and pulp waste.

6. The process of claim 5, wherein the binder is a pulp waste.

7. The processing technology of claim 1, wherein the mass ratio of the natural stone aggregate to the filler to the binder is 8-10: 4-7: 1.

8. The process according to claim 1, which comprisesCharacterized in that the vibration force is 70N-100N/cm²。

9. The machining process according to claim 1, wherein the vibration frequency of the vibration unit is 4000 to 6000 r/min.

10. The process according to claim 1, wherein the curing agent used for curing is methyl ethyl ketone peroxide, cycloethanone peroxide, tert-butyl 2-ethylhexanoate peroxide.

Technical Field

The invention relates to the field of industry, in particular to a low-cost industrial synthetic stone processing technology.

Background

As a necessary basic building material, natural stone has the following five properties: the natural stone is easy to obtain, machine-shaping and transport, and has excellent mechanical property, durability and wide application, but the natural stone is gradually limited to be mined along with the reasons of excessive increase of mining amount, low mining utilization rate and the like, and the product of each mining area has unique color and variety, so that the difficulty in use is increased. People are always looking for alternatives. With the gradual improvement of living standard of people, the synthetic stone is more and more popular to people as a novel building material due to beautiful color, novel pattern and elegant decorative effect, and various synthetic stones are produced.

The existing synthetic stone production mainly adopts vacuum vibration, compression molding process and matched equipment, although the prepared synthetic stone product has higher compactness, the production cost is high, a large amount of polyester resin is needed to be used as an adhesive, the price of the polyester resin is high (the current market price is 1.5 ten thousand yuan/ton), and the synthetic stone decorative plate can release harmful gas when being used in a large amount, so that the indoor environmental protection standard can not be met. For example, in the synthetic stone product called Dahua in the market, the stone material with the grain diameter of 3.5-12 cm is used only in an amount of less than 40%, so that the flower color formed in the integral stirring and vibration pressing does not depart from the category of colored concrete. In addition, from the viewpoint of mineral resource utilization, only a few kinds of marbles such as rosin yellow and snow white are currently used as synthetic stone raw materials commonly called as granite, and other wastes such as construction solid wastes and powder residues generated in industry are mostly discarded and cannot be reasonably utilized.

Disclosure of Invention

The invention mainly solves the technical problem of providing a low-cost industrial synthetic stone processing technology which can reduce the production cost of synthetic stones, and the obtained synthetic stones have high compactness and strength and are not easy to bend and deform.

In order to solve the technical problems, the invention adopts a technical scheme that:

a low-cost industrial synthetic stone processing technology comprises the following steps:

(1) mixing natural stone aggregate, filler and adhesive to form a mixture;

(2) the mixture is flatly arranged in a die frame according to the required thickness, and the bottom surface and the top surface of the mixture are respectively provided with a demoulding layer;

(3) vacuum exhausting the mixture and conveyingPressing in a forming device, vibrating the material in different zones, wherein each zone needs a vibration unit, a template is arranged between the vibration unit and the mixture, all the vibration units vibrate on the template in different zones, and the vibration force of the vibration units is 40-120N/cm²；

(4) And curing the formed mixture to obtain a finished product.

In the process of forming the thin plate, the material is subjected to partition vibration, each partition needs one vibration unit, the limitation of vibration equipment on the size of the plate can be solved, and the partition amount can be increased according to the required size, so that the plate with any size can be manufactured.

In a particular embodiment of the invention, the filler is selected from the group consisting of construction-based solid waste, industrially produced powdery residues, cement, sand and soil.

Further, the building solid waste comprises waste wood boards, waste plastic boards, waste ceramsite, waste polyphenyl particle boards and waste metals.

Further, the industrially produced powdery residue includes industrially produced fly ash, coal ash or fly ash.

In a specific embodiment of the invention, the adhesive comprises one or more of epoxy resin, starch, polystyrene, polyacrylate and pulp waste liquid.

Further, the adhesive is pulp waste.

In a specific embodiment of the invention, the mass ratio of the natural stone aggregate, the filler and the binder is 8-10: 4-7: 1.

In a specific embodiment of the present invention, the vibration force is 70N to 100N/cm²。

In the specific embodiment of the invention, the vibration frequency of the vibration unit is 4000-6000 r/min.

The inventor finds that the vibration force is not between 70N and 100N/cm through numerous experimental researches²And/or when the vibration frequency is not in the range of 4000-6000 r/min, the obtained plate has low density and small hardness.

In a specific embodiment of the present invention, the curing agent used for the curing is methyl ethyl ketone peroxide, cycloethyl ketone peroxide, or tert-butyl 2-ethylhexanoate peroxide.

Compared with the prior art, the invention has the following beneficial effects:

(1) the synthetic stone has the advantages of high strength, high density, high hardness and difficult bending deformation.

(2) The invention can increase the partition quantity according to the required size, thereby manufacturing the plate with any size.

(3) The invention adopts the pulp waste liquid as the adhesive and the building solid waste and the powder residue produced by industry as the filler, thereby obviously reducing the production cost.

Detailed Description

The technical solutions of the present invention are described clearly and completely below, and it is obvious that the described embodiments are some, not all embodiments of the present invention. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, are within the scope of the present invention.

Example 1

(1) Mixing natural stone aggregate, cement, waste wood boards, 3 fillers of waste ceramsite and pulp waste liquid according to the weight ratio of the natural stone aggregate: filling materials: and mixing the pulp waste liquid in a mass ratio of 8:4:1 to form a mixture.

(2) The mixture is flatly arranged in a die frame according to the required thickness, and the bottom surface and the top surface of the mixture are respectively provided with a demoulding layer.

(3) The method comprises the steps of conveying a mixture into a forming device for pressing after vacuum exhaust, carrying out partition vibration on the material, wherein each partition needs a vibration unit, a template is arranged between each vibration unit and the mixture, all the vibration units vibrate on the template in a partition mode, and the vibration force of each vibration unit is 120N/cm²The vibration frequency was 4000/min.

(4) And adding 0.03% of methyl ethyl ketone peroxide to solidify the formed mixture to obtain a finished product.

Example 2

(1) Mixing natural stone aggregate, cement, waste polyphenyl particle boards, 3 fillers of waste metals and pulp waste liquid according to the following ratio: filling materials: mixing the pulp waste liquid in a mass ratio of 10:4:1 to form a mixture.

(2) The mixture is flatly arranged in a die frame according to the required thickness, and the bottom surface and the top surface of the mixture are respectively provided with a demoulding layer.

(3) The method comprises the steps of conveying a mixture into a forming device for pressing after vacuum exhaust, carrying out partition vibration on the material, wherein each partition needs a vibration unit, a template is arranged between each vibration unit and the mixture, all the vibration units vibrate on the template in a partition mode, and the vibration force of each vibration unit is 40NN/cm²The vibration frequency was 6000 r/min.

(4) And adding 0.03% of methyl ethyl ketone peroxide to solidify the formed mixture to obtain a finished product.

Example 3

(1) Mixing natural stone aggregate, cement, waste wood boards, waste plastic boards, 4 fillers of waste metals and paper pulp waste liquid according to the following ratio: filling materials: mixing the pulp waste liquid in a mass ratio of 9:5:1 to form a mixture.

(2) The mixture is flatly arranged in a die frame according to the required thickness, and the bottom surface and the top surface of the mixture are respectively provided with a demoulding layer.

(3) The method comprises the steps of conveying a mixture into a forming device for pressing after vacuum exhaust, carrying out partition vibration on the material, wherein each partition needs a vibration unit, a template is arranged between each vibration unit and the mixture, all the vibration units vibrate on the template in a partition mode, and the vibration force of each vibration unit is 50N/cm²The vibration frequency is 5000 r/min.

(4) Adding 0.03% of cycloethanone peroxide to solidify the formed mixture to obtain a finished product.

Example 4

(1) Mixing natural stone aggregate, cement, waste wood boards, waste plastic boards, waste ceramsite, 5 fillers of waste polyphenyl particle boards and pulp waste liquid according to the proportion of the natural stone aggregate: filling materials: mixing the pulp waste liquid in a mass ratio of 10:4:1 to form a mixture.

(2) The mixture is flatly arranged in a die frame according to the required thickness, and the bottom surface and the top surface of the mixture are respectively provided with a demoulding layer.

(3) The method comprises the steps of conveying a mixture into a forming device for pressing after vacuum exhaust, carrying out partition vibration on the material, wherein each partition needs a vibration unit, a template is arranged between each vibration unit and the mixture, all the vibration units vibrate on the template in a partition mode, and the vibration force of each vibration unit is 100N/cm²The vibration frequency was 4500 r/min.

(4) And adding 0.03% of tert-butyl peroxy-2-ethylhexanoate to solidify the formed mixture to obtain a finished product.

Example 5

(1) Mixing natural stone aggregate, cement, waste wood boards, waste plastic boards, waste ceramsite, waste polyphenyl particle boards, 6 fillers of waste metals and paper pulp waste liquid according to the proportion of the natural stone aggregate: filling materials: mixing the pulp waste liquid in a mass ratio of 9:7:1 to form a mixture.

(2) The mixture is flatly arranged in a die frame according to the required thickness, and the bottom surface and the top surface of the mixture are respectively provided with a demoulding layer.

(3) The method comprises the steps of conveying a mixture into a forming device for pressing after vacuum exhaust, carrying out partition vibration on the material, wherein each partition needs a vibration unit, a template is arranged between each vibration unit and the mixture, all the vibration units vibrate on the template in a partition mode, and the vibration force of each vibration unit is 80N/cm²The vibration frequency is 5500 r/min.

(4) Adding 0.03% of cycloethanone peroxide to solidify the formed mixture to obtain a finished product.

Example 6

(1) Mixing natural stone aggregate, cement, industrially produced fly ash, 3 kinds of fillers of coal ash and pulp waste liquid according to the following ratio: filling materials: mixing the pulp waste liquid in a mass ratio of 9:4:1 to form a mixture.

(2) The mixture is flatly arranged in a die frame according to the required thickness, and the bottom surface and the top surface of the mixture are respectively provided with a demoulding layer.

(3) The method comprises the steps of conveying a mixture into a forming device for pressing after vacuum exhaust, carrying out partition vibration on the material, wherein each partition needs a vibration unit, a template is arranged between each vibration unit and the mixture, all the vibration units vibrate on the template in a partition mode, and the vibration force of each vibration unit is 60N/cm²The vibration frequency is 4000 r/min.

(4) And adding 0.03% of methyl ethyl ketone peroxide to solidify the formed mixture to obtain a finished product.

Example 7

(1) Mixing natural stone aggregate, waste ceramsite, waste polyphenyl particle board, waste metal, 4 fillers of ash and pulp waste liquid according to the following ratio: filling materials: mixing the pulp waste liquid in a mass ratio of 8:5:1 to form a mixture.

(2) The mixture is flatly arranged in a die frame according to the required thickness, and the bottom surface and the top surface of the mixture are respectively provided with a demoulding layer.

(3) The method comprises the steps of conveying a mixture into a forming device for pressing after vacuum exhaust, carrying out partition vibration on the material, wherein each partition needs a vibration unit, a template is arranged between each vibration unit and the mixture, all the vibration units vibrate on the template in a partition mode, and the vibration force of each vibration unit is 100N/cm²The vibration frequency was 4800 r/min.

(4) Adding 0.03% of tert-butyl peroxy-2-ethylhexanoate, and curing the formed mixture to obtain a finished product.

Example 8

(1) Mixing natural stone aggregate, waste wood boards, waste plastic boards, waste ceramic granules, waste polyphenyl granule boards, waste metals and pulp waste liquid according to the following ratio: filling materials: mixing the pulp waste liquid in a mass ratio of 8:4:1 to form a mixture.

(2) The mixture is flatly arranged in a die frame according to the required thickness, and the bottom surface and the top surface of the mixture are respectively provided with a demoulding layer.

(3) The mixture is vacuumized and then is sent into a forming device for pressing, the materials are vibrated in different areas, each area needs a vibration unit, and a vibration unit is arranged between the vibration unit and the mixtureIs provided with a template, all vibration units vibrate on the template in a subarea way, and the vibration force of the vibration units is 40N/cm²The vibration frequency was 5600 r/min.

(4) Adding 0.03% of tert-butyl peroxy-2-ethylhexanoate, and curing the formed mixture to obtain a finished product.

Example 9

(1) Mixing natural stone aggregate, cement, waste wood boards, waste plastic boards, waste ceramsite, waste polyphenyl particle boards, 6 fillers of waste metals and paper pulp waste liquid according to the proportion of the natural stone aggregate: filling materials: mixing the pulp waste liquid in a mass ratio of 10:4:1 to form a mixture.

(2) The mixture is flatly arranged in a die frame according to the required thickness, and the bottom surface and the top surface of the mixture are respectively provided with a demoulding layer.

(3) The method comprises the steps of conveying a mixture into a forming device for pressing after vacuum exhaust, carrying out partition vibration on the material, wherein each partition needs a vibration unit, a template is arranged between each vibration unit and the mixture, all the vibration units vibrate on the template in a partition mode, and the vibration force of each vibration unit is 120N/cm²The vibration frequency is 5500 r/min.

(4) Adding 0.03% of cycloethanone peroxide to solidify the formed mixture to obtain a finished product.

Example 10

(1) Mixing natural stone aggregate, waste wood boards, waste plastic boards, waste ceramic granules, waste polyphenyl granule boards, waste metals and pulp waste liquid according to the following ratio: filling materials: mixing the pulp waste liquid in a mass ratio of 9:4:1 to form a mixture.

(2) The mixture is flatly arranged in a die frame according to the required thickness, and the bottom surface and the top surface of the mixture are respectively provided with a demoulding layer.

(3) The method comprises the steps of conveying a mixture into a forming device for pressing after vacuum exhaust, carrying out partition vibration on the material, wherein each partition needs a vibration unit, a template is arranged between each vibration unit and the mixture, all the vibration units vibrate on the template in a partition mode, and the vibration force of each vibration unit is 70N/cm²The vibration frequency is 5200 r/min.

(4) And adding 0.03% of methyl ethyl ketone peroxide to solidify the formed mixture to obtain a finished product.

Comparative example

(1) Mixing natural stone aggregate, cement, 2 fillers of polymer composite materials and unsaturated polyester resin according to the following ratio: filling materials: the unsaturated polyester resins were mixed in a mass ratio of 8:4:1 to form a mixed material.

(2) The mixture is flatly arranged in a die frame according to the required thickness, and the bottom surface and the top surface of the mixture are respectively provided with a demoulding layer.

(3) The method comprises the steps of conveying a mixture into a forming device for pressing after vacuum exhaust, carrying out partition vibration on the material, wherein each partition needs a vibration unit, a template is arranged between each vibration unit and the mixture, all the vibration units vibrate on the template in a partition mode, and the vibration force of each vibration unit is 30N/cm²The vibration frequency was 3000/min.

(4) And adding 0.03% of methyl ethyl ketone peroxide to solidify the formed mixture to obtain a finished product.

Compared with the comparative example, in the examples 1 to 10, the pulp waste liquid is used as the adhesive, the building solid waste and the powder residues generated in the industry are used as the filler, the production cost is reduced by 3 to 4.5 ten thousand yuan/ton, and the obtained synthetic stone has the advantages of high strength, high density, high hardness and difficult bending deformation.

Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.