Environment-friendly artificial stone with low cost and high strength and a preparation method thereof

Abstract

The invention relates to an environment-friendly artificial stone with low cost and high strength and a preparation method thereof, the artificial stone comprises the following raw materials in parts by mass: 60-80 parts of fritted sand; 10-30 parts of quartz powder; 9-14 parts of terephthalic unsaturated polyester resin; 0.6-1 parts of curing agent; 0.8-1 parts of coupling agent; 0.5-1 parts of pigment paste; 0.1-1 parts of pigment powder. The invention has advantages of: (1) using mine solid waste or waste materials as raw materials, and using blast-furnace gas and coke-oven gas recovered and purified in the productive process of the steel plant and coking plant as fuel, the production process is green and environment-friendly, which can recycle waste materials. (2) high strength, natural stripe, elegance appearance, green and environmental protection, and being recognized by global customers and promising in worldwide market.

Claims

1. An environment-friendly artificial stone with low cost and high strength, comprising the following raw materials in parts by mass: TABLE-US-00009 fritted sand 60-80 parts quartz powder 10-30 parts terephthalic unsaturated polyester resin 9-14 parts curing agent 0.6-1 parts coupling agent 0.8-1 parts pigment paste 0.5-1 parts pigment powder 0.1-1 parts; wherein, the flitted sand comprises the following components as mass percent: TABLE-US-00010 Al.sub.2O.sub.3 1-10% SiO.sub.2 60-80%  Fe.sub.2O.sub.3 0.1-0.5%  CaO 5-10% MgO  2-5% K.sub.2O 0.2-2%  Na.sub.2O 5-15% TiO.sub.2 0.1-2%.

2. The environment-friendly artificial stone with low cost and high strength of claim 1, wherein a flexural strength of environment-friendly artificial stone with low cost and high strength is 80-115 Mpa.

3. The environment-friendly artificial stone with low cost and high strength of claim 1, wherein the fritted sand comprises the fritted sand of 8-16 mesh, 16-26 mesh, 26-40 mesh, 40-70 mesh, 70-120 mesh and/or 120-200 mesh.

4. The environment-friendly artificial stone with low cost and high strength of claim 1, wherein the fritted sand is obtained by melting tailing quartz, coal gangue, limestone, sodium feldspar and potassium feldspar in a mass ratio of 7-10:4-6:1-2:1-3:1-3 at a high temperature of 1200° C.-1400° C., and then quenching in chilled water.

5. The environment-friendly artificial stone with low cost and high strength of claim 1, wherein mesh range of the quartz powder is 300-1000 mesh.

Description

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(1) The invention will be further described in detail below with reference to the embodiments, but the embodiments of the invention are not limited thereto.

Embodiment 1

(2) An environment-friendly artificial stone with low cost and high strength, the consumption of each raw material (parts by mass) is:

(3) TABLE-US-00003 fritted sand of 26-40 mesh 35 parts fritted sand of 40-70 mesh 30 parts tailing quartz powder 20 parts terephthalic unsaturated polyester resin 12.0 parts tert-Butylperoxy-2-ethylhecanoate 1.0 part γ-methacryloxy propyl trimethoxyl silane 1.0 part composite pigment paste 0.5 parts composite pigment powder 0.5 parts

(4) wherein, the fritted sand comprises following chemical components:

(5) TABLE-US-00004 Al.sub.2O.sub.3 2.8% SiO.sub.2 71.7% Fe.sub.2O.sub.3 0.1% CaO 7.5% MgO 3.5% K.sub.2O 0.8% Na.sub.2O 13.5% TiO.sub.2 0.1%

(6) the tailing quartz powder is quartz powder of 350 mesh;

(7) The composite pigment paste is a mixture of titanium white paste, scarle paste and iron yellow paste in a ratio of (mass fraction) of 7:1:2.

(8) The composite pigment powder is a mixture of titanium white powder, iron red powder and phthalo blue powder in a ratio of (mass fraction) of 6:1:1.

(9) In the embodiment, a preparation method of an environment-friendly artificial stone with low cost and high strength, comprising the following steps:

(10) (1) a premixture was prepared by mixing tert-Butylperoxy-2-ethylhecanoate, γ-methacryloxy propyl trimethoxyl silane, composite pigment paste and terephthalic unsaturated polyester resin; and fritted sand of 26-40 mesh and that of 40-70 mesh are obtained by melting tailing quartz sand, coal gangue, limestone, sodium feldspar and potassium feldspar in a mass ratio of 8:5:1:2:1 at a high temperature of 1350° C. in the rotary frit furnace by using blast-furnace gas and coke-oven gas recovered and purified in the productive process of the steel plant and coking plant as the fuel, and then quenching in chilled water.

(11) (2) stirring and mixing the fritted sand, the tailing quartz sand and the premixture for 10 minutes according to the steps of rotating at a low frequency of 10 Hz for 2 minutes, reversing at a low frequency of 10 Hz for 2 minutes, rotating at a high frequency of 50 Hz for 3 minutes, and stirring at a high frequency of 50 Hz for 3 minutes for 10 minutes;

(12) (3) adding the mixture in step (2) on a mould plate and spraying composite pigment powder;

(13) (4) putting the product obtained in step (3) into a pressing machine, vacuumizing, vibrating and forming at eight frequency bands in sequence: 30 seconds at 25 Hz, 30 seconds at 30 Hz, 30 seconds at 35 Hz, 30 seconds at 40 Hz, 30 seconds at 45 Hz, 30 seconds at 50 Hz, and then putting the pressed plate into curing oven and flatwise sizing for 24 hours after 85° C. curing for 120 minutes;

(14) (5) after keeping thickness by putting the abovementioned embryonic plate into polishing machine and fine polishing by 26-6000 mesh abrasion block, the environment-friendly artificial stone with low cost and high strength is obtained.

(15) The raw materials and steps remain the same to prepare a conventional artificial quartz sand composite plate, except that using 26-70 mesh quartz sand instead of the fritted sand.

(16) The obtained environment-friendly artificial stone with low cost and high strength and conventional artificial quartz sand composite plate are tested for mechanics performance, wherein three test results of the flexural strength of the conventional artificial quartz sand composite plate are 60.3 MPa, 60.5 MPa and 60.6 MPa respectively, and the average value was 60.5 MPa; three test results of the flexural strength of the new artificial stone with high performance and low cost synthesized by the environment-friendly materials are 107 MPa, 105 MPa and 106 MPa respectively, and the average value was 106 MPa, which is improved about 75% comparing with the flexural strength of the conventional artificial quartz sand composite plate; In addition, three falling ball impact strength tests are carried out on the environmentally-friendly artificial stone with low cost and high strength, and the results are 135 cm, 137 cm and 136 cm respectively, and the average value was 136 cm.

Embodiment 2

(17) An environment-friendly artificial stone with low cost and high strength, comprising the following raw materials in parts by mass:

(18) TABLE-US-00005 fritted sand of 40-70 mesh 50 parts fritted sand of 70-120 mesh 24 parts tailing quartz powder 11 parts terephthalic unsaturated polyester resin 12.5 parts tert-Butylperoxy-2-ethylhecanoate 0.8 parts γ-methacryloxy propyl trimethoxyl silane 0.7 parts composite pigment paste 0.6 parts composite pigment powder 0.4 parts

(19) wherein, the fritted sand comprises following chemical components:

(20) TABLE-US-00006 Al.sub.2O.sub.3 1.8% SiO.sub.2 73.5% Fe.sub.2O.sub.3 0.15% CaO 7.8% MgO 3.8% K.sub.2O 1.2% Na.sub.2O 11.5% TiO.sub.2 0.2%

(21) the tailing quartz powder is quartz powder of 450 mesh;

(22) The composite pigment paste is a mixture of titanium white paste, carbon black paste and iron yellow paste in a ratio of (mass fraction) of 6:3:2.

(23) The composite pigment powder is a mixture of titanium white powder, iron black powder and iron yellow powder, in a ratio of (mass fraction) of 5:2:1.

(24) In the embodiment, a preparation method of an environment-friendly artificial stone with low cost and high strength, comprising the following steps:

(25) (1) a premixture was prepared by mixing tert-Butylperoxy-2-ethylhecanoate, γ-methacryloxy propyl trimethoxyl silane, composite pigment paste and terephthalic unsaturated polyester resin; and fritted sand of 40-70 mesh and that of 70-120 mesh are obtained by melting tailing quartz sand, coal gangue, limestone, sodium feldspar and potassium feldspar in a mass ratio of 9:4:1:1:1 at a high temperature of 1400° C. in the rotary frit furnace by using blast-furnace gas and coke-oven gas recovered and purified in the productive process of the steel plant and coking plant as the fuel, and then quenching in chilled water.

(26) (2) stirring and mixing the fritted sand, the tailing quartz sand and the premixture for 10 minutes according to the steps of rotating at a low frequency of 10 Hz for 2 minutes, reversing at a low frequency of 10 Hz for 2 minutes, rotating at a high frequency of 50 Hz for 3 minutes, and stirring at a high frequency of 50 Hz for 3 minutes for 10 minutes;

(27) (3) adding the mixture in step (2) on a mould plate and spraying composite pigment powder;

(28) (4) putting the product obtained in step (3) into a pressing machine, vacuumizing, vibrating and forming at eight frequency bands in sequence: 30 seconds at 25 Hz, 30 seconds at 30 Hz, 30 seconds at 35 Hz, 30 seconds at 40 Hz, 30 seconds at 45 Hz, 30 seconds at 50 Hz, and then putting the pressed plate into curing oven and flatwise sizing for 24 hours after 90° C. curing for 110 minutes;

(29) (5) after keeping thickness by putting the abovementioned embryonic plate into polishing machine and fine polishing by 26-6000 mesh abrasion block, the environment-friendly artificial stone with low cost and high strength is obtained.

(30) The raw materials and steps remain the same to prepare a conventional artificial quartz sand composite plate, except that using 26-70 mesh quartz sand instead of the fritted sand.

(31) The obtained environment-friendly artificial stone with low cost and high strength and conventional artificial quartz sand composite plate are tested for mechanics performance, wherein three test results of the flexural strength of the conventional artificial quartz sand composite plate are 60.3 MPa, 60.5 MPa and 60.6 MPa respectively, and the average value was 60.5 MPa, three test results of the flexural strength test of the new artificial stone with high performance and low cost synthesized by the environment-friendly materials are 110 MPa, 112 MPa and 113 MPa respectively, and the average value was 111 MPa, which is improved about 82% comparing with the flexural strength of the conventional artificial quartz sand composite plate; In addition, three falling ball impact strength tests are carried out on the new artificial stone with high performance and low cost synthesized by the environment-friendly materials, and the results are 137 cm, 139 cm, and 138 cm respectively, and the average value was 138 cm.

Embodiment 3

(32) An environment-friendly artificial stone with low cost and high strength, the consumption of each raw material (parts by mass) is:

(33) TABLE-US-00007 fritted sand of 8-16 mesh 8 parts fritted sand of 16-26 mesh 15 parts fritted sand of 26-40 mesh 18 parts fritted sand of 40-70 mesh 30 parts tailing quartz powder 16 parts terephthalic unsaturated polyester resin 11.0 parts tert-Butylperoxy-2-ethylhecanoate 0.7 parts γ-methacryloxy propyl trimethoxyl silane 0.6 parts composite pigment paste 0.5 parts composite pigment powder 0.2 parts

(34) wherein, the fritted sand comprises following chemical components:

(35) TABLE-US-00008 Al.sub.2O.sub.3 4.8% SiO.sub.2 68.0% Fe.sub.2O.sub.3 0.1% CaO 8.6% MgO 3.7% K.sub.2O 1.0% Na.sub.2O 13.5% TiO.sub.2 0.3%

(36) The fritted sand is fritted particles of 8-16 mesh, 16-26 mesh, 26-40 mesh and 40-70 mesh which are obtained by melting tailing quartz sand, coal gangue, limestone, sodium feldspar and potassium feldspar in a mass ratio of 9:3:1:1:2 at a high temperature of 1380° C. in the rotary frit furnace by using blast-furnace gas and coke-oven gas recovered and purified in the productive process of the steel plant and coking plant as the fuel, and then quenching in chilled water.

(37) the tailing quartz powder is quartz powder of 500 mesh;

(38) The composite pigment paste is a mixture of titanium white paste, scarle paste and iron black paste in a ratio of (mass fraction) of 9:3:1.

(39) The composite pigment powder is a mixture of titanium white powder, iron black powder and metal powder, in a ratio of (mass fraction) of 5:1:2.

(40) In the embodiment, a preparation method of an environment-friendly artificial stone with low cost and high strength, comprising the following steps:

(41) (1) a premixture was prepared by mixing tert-Butylperoxy-2-ethylhecanoate, γ-methacryloxy propyl trimethoxyl silane, composite pigment paste and terephthalic unsaturated polyester resin; and fritted sand of 8-16 mesh, 16-26 mesh, 26-40 mesh and 40-70 mesh are obtained by melting tailing quartz sand, coal gangue, limestone, sodium feldspar and potassium feldspar in a mass ratio of 9:3:1:1:2 at a high temperature of 1380° C., and then quenching in chilled water.

(42) (2) stirring and mixing the fritted sand, the tailing quartz sand and the premixture for 10 minutes according to the steps of rotating at a low frequency of 10 Hz for 2 minutes, reversing at a low frequency of 10 Hz for 2 minutes, rotating at a high frequency of 50 Hz for 3 minutes, and stirring at a high frequency of 50 Hz for 3 minutes for 10 minutes;

(43) (3) adding the mixture in step (2) on a mould plate and spraying composite pigment powder;

(44) (4) putting the product obtained in step (3) into a pressing machine, vacuumizing, vibrating and forming at eight frequency bands in sequence: 40 seconds at 20 Hz, 30 seconds at 30 Hz, 30 seconds at 35 Hz, 30 seconds at 40 Hz, 60 seconds at 45 Hz, 30 seconds at 50 Hz, and then putting the pressed plate into curing oven and flatwise sizing for 24 hours after 90° C. curing for 100 minutes;

(45) (5) after keeping thickness by putting the abovementioned embryonic plate into polishing machine and fine polishing by 26-6000 mesh abrasion block, the environment-friendly artificial stone with low cost and high strength is obtained.

(46) The raw materials and steps remain the same to prepare a conventional artificial quartz sand composite plate, except that using 26-70 mesh quartz sand instead of the fritted sand.

(47) The obtained environment-friendly artificial stone with low cost and high strength and conventional artificial quartz sand composite plate are tested for mechanics performance, wherein three test results of the flexural strength of the conventional artificial quartz sand composite plate are 60.3 MPa, 60.5 MPa and 60.6 MPa respectively, and the average value was 60.5 MPa; three test results of the flexural strength test of the new artificial stone with high performance and low cost synthesized by the environment-friendly materials are 104 MPa, 103 MPa and 106 MPa respectively, and the average value was 104 MPa, which is improved about 72% comparing with the flexural strength of the conventional artificial quartz sand composite plate; In addition, three falling ball impact strength tests are carried out on the new artificial stone with high performance and low cost synthesized by the environment-friendly materials, and the results are 133 cm, 135 cm, and 134 cm respectively, and the average value was 134 cm.

(48) The above embodiments are the better embodiments of the invention, however, embodiments of the invention are not limited thereto, and any other changes, modifications, replacements, combinations and simplifications made without departing from the spirit and principle of the invention, should be covered in the protection scope of the invention.