Patent Description:
As the country strengthens ecological and environmental protection, exploitation of natural stone mines is strictly controlled. China's infrastructure construction, such as airports, subway stations, high-speed rail stations, commercial plaza and hall centers, however, is aggressively developing. A large amount of artificial stone panel materials are required as a result. The artificial stone that replaces the natural stone has broad market prospects.

Traditional artificial stone is typically composed of organic resin and smaller amounts of inorganic material. The resin artificial stone has several disadvantages. In addition to deformation and cracking due to heating, exposure to ultraviolet radiation and elevated temperatures weaken the strength and cause aging and discoloration. Moreover, the resin artificial stone may produce an unpleasant smell during combustion, be hardly degraded and have short service life. Therefore, use of the resin artificial stone has been gradually restricted because of the potential harm it may cause to the environment. Currently, novel inorganic artificial stone panels are mainly traditional cement-based terrazzo products, which have numerous shortcomings, including low compressive strength, poor hardness, poor bending strength, brittle, high overall water absorption rate and poor resistance to pollution and chemical performance. Thus, novel inorganic artificial stone panels possess undesirable physical and mechanical properties compared to the natural stones.

The current inorganic artificial stone is inherently brittle and easily broken when put under pressure. Artificial stone panel typically has a single-layer structure, and the bottom is directly cracked to produce brittle fracture when suffering from an external force. The structure's low ductility directly leads to product damage. In this regard, a metal mesh or fiber mesh reinforced structure, such as that disclosed in <CIT>, may be added to the middle of the structure locally to reinforce it. The brittle bottom, however, still bends and deforms to produce brittle cracks due to the applied force. Although the reinforced mesh improves tensile strength and relieves formation of cracks to some extent, as applied force increases, the structure eventually succumbs to deformation, crack propagation and destruction. Another structure disclosed in <CIT> uses a toughening plate formed by combining a surface layer with a direct fiber substrate to solve the problem of deformation and cracks of the surface layer due to compression. The introduction of fiber substrate, however, causes fiber exposure out of the surface and forms fiber channel hole in the bottom scraping during manufacture of the artificial stone panel, which results in unwanted increases in water absorption for the panel structure. If metal fiber is used, corrosion damage and metal corrosion pollution phenomenon may be induced. If other fiber is used, the unwanted increase in water absorption rate may appear, which has a deleterious effect on the mechanical properties and durability of the panel. <CIT> discloses a kind of artificial marble sheet material with decorative effect.

In view of this, the present invention provides a high toughness inorganic composite artificial stone panel having a multilayer composite structure, which shows high strength, pollution resistance, high toughness, long service life, aging resistance and economic rationality.

According to the present invention, the high toughness inorganic composite artificial stone panel includes: a surface layer, an intermediate metal fiber toughening layer and a substrate toughening layer. The surface layer includes the following raw material components in parts by weight: <NUM>-<NUM> parts of quartz sand, <NUM>-<NUM> parts of quartz powder, <NUM>-<NUM> parts of inorganic active powder, <NUM>-<NUM> parts of pigment, <NUM>-<NUM> part of water reducer and <NUM>-<NUM> parts of water. The intermediate metal fiber toughening layer includes the following raw material components in parts by weight: <NUM>-<NUM> parts of inorganic active powder, <NUM>-<NUM> parts of sand, <NUM>-<NUM> parts of water reducer, <NUM>-<NUM> parts of water and <NUM>-<NUM> parts of metal fiber. The substrate toughening layer includes the following raw material components in parts by weight: <NUM>-<NUM> parts of inorganic active powder, <NUM>-<NUM> parts of quartz sand, <NUM>-<NUM> parts of quartz powder, <NUM>-<NUM> parts of water reducer, <NUM>-<NUM> parts of water and <NUM>-<NUM> parts of toughening agent, the quartz sand has a fineness modulus of <NUM>-<NUM>, a content of silicon dioxide above <NUM>% and a hardness of a raw stone above <NUM> Mohs and is free of impurities and weathering and the quartz powder has a fineness of <NUM> mesh or more, a content of silicon dioxide above <NUM>%, a hardness of a raw stone above <NUM> Mohs.

In the present invention, a core function of the quartz powder lies in improving abrasion resistance and scratch resistance of hydration products of cementitious powder except for aggregate on a surface of the artificial stone after mixing, and improving a surface density.

Further, the inorganic active powder is mainly composed of pure white Portland cement having a strength grade of more than <NUM> doped with one or more active powders selected from the group consisting of white silicon powder, mineral powder, nano calcium oxide, nano silicon oxide, and sintered high white kaolin powder. The color of the active powder is simply white with a whiteness index exceeding <NUM>, and an activity index is detected to be greater than <NUM>%. This ensures the good stability of subsequent color regulation while keeping material strength. A ratio of cement to other active powder is <NUM>:<NUM>-<NUM>.

Further, the pigments are inorganic pigments of various colors.

Further, the water reducer does not have a metal ion color, the concentration of the water reducer is no more than <NUM>%, a water reduction rate of the water reducer is more than <NUM>%, and the retarding time is <NUM>-<NUM> hour.

Further, the sand is one or more selected from the group consisting of river sand, manufactured sand and quartz sand, is required to exclude mud, mud block and organic shellfish, and has material firmness quality loss of not greater than <NUM>%, a maximum particle diameter of not greater than <NUM>, and a fineness modulus of less than <NUM> and greater than <NUM>.

Further, the metal fiber includes one or more of metal fibers having a diameter range of <NUM>-<NUM>, an aspect ratio of <NUM>-<NUM>, and a tensile strength of greater than <NUM> MPa.

Further, the toughening agent is one or more of latexes such as polyvinyl alcohol glue, acrylamide glue and so on.

Further, an overall thickness of the panel is <NUM>-<NUM>, a thickness of the surface layer is <NUM>-<NUM>, and a thickness of the substrate layer is <NUM>-<NUM>.

The present invention further provides a preparation method of the high toughness inorganic composite artificial stone panel, including the following steps:.

Further, in step <NUM>, the stirring time and the mixing time are not less than <NUM> minutes, respectively, and Vebe consistometer test time of working performance of the stirring material is <NUM>-<NUM> seconds; and initial setting time after the stirring and mixing is not less than <NUM> minutes.

Further, in step S3, and the time for the vacuum exhaust is not less than <NUM> seconds, the time for the compression is not less than <NUM> seconds; and a vacuum pressure is -<NUM>-<NUM> MPa, a pressure load of the vacuum-press is not less than <NUM> MPa, and a pressure is not less than <NUM> kN.

Further, in step S4, humidity is kept above <NUM>% during the high temperature curing process.

The process performs centralized pressing by a continuously hierarchical material arrangement manner to make materials between layers intermesh with each other so as to avoid an interface separation phenomenon under compression. Compared to conventional vacuum process of preparing inorganic stone, pressing pressure is increased and vacuuming time is shortened, compactness and production efficiency of artificial stone are improved, water absorption rate of a panel surface is reduced. The volume of artificial stone panel becomes more stable while improving use efficiency of mold in early stage by staged curing through adjusting temperature and preserving moisture, and completely overcomes shrinkage performance to ensure stable consistency of strength throughout the life of the panel.

According to the present invention, the high toughness composite artificial stone panel has advantages of high strength, high bending resistance, low brittleness, impact resistance, crack resistance and good aseismic performance. Moreover, the volume is stable with low shrinkage, no warping deformation occurs during use, the water absorption is extremely low, the durability is good and no aging issues exist. The various layers are firmly bonded. The structure is highly safe with good ductility and, therefore, has no instant brittle fracture. The structure is able to be used as a bearing structure with good surface pollution resistance. The structure has a wide material resource, a low overall and comprehensive construction cost, and is suitable for promotion and use.

Further advantages, features and potential applications of the present invention may be gathered from the description which follows, in conjunction with the embodiments illustrated in the drawings.

Figure is a schematic diagram showing a structure of a high toughness inorganic composite artificial stone panel.

Illustration of reference signs: surface layer <NUM>, intermediate metal fiber toughening layer <NUM>, and substrate toughening layer <NUM>.

The drawings are for illustrative purposes only and cannot be construed as limitations to the invention. In order to better explain the present embodiment, some parts in the drawings may be omitted, enlarged or shrunk, and do not represent a size of an actual product. To those skilled in the art, it may be understandable that some well-known structures in the drawings and the description thereof may be omitted. The positional relationship described in the drawings is only for illustrative purposes and cannot be construed as limitations to the invention. Below the present invention will be further explained in detail in conjunction with exemplary embodiments.

As shown in the figure, a high toughness inorganic composite artificial stone panel having an overall thickness (t1+t2+t3) of <NUM>-<NUM>, includes a surface layer having a thickness t1 of <NUM>-<NUM>, an intermediate metal fiber toughening layer t2 and a substrate toughening layer having a thickness t3 of <NUM>-<NUM>. The surface layer includes the following raw material components in parts by weight: <NUM> parts of quartz sand, <NUM> parts of quartz powder, <NUM> parts of inorganic active powder, <NUM> parts of pigment, <NUM> parts of water reducer, and <NUM> parts of water. The intermediate metal fiber toughening layer includes the following raw material components in parts by weight: <NUM> parts of inorganic active powder, <NUM> parts of sand, <NUM> parts of water reducer, <NUM> parts of water, and <NUM> parts of metal fiber. The substrate toughening layer includes the following raw material components in parts by weight: <NUM> parts of inorganic active powder, <NUM> parts of quartz sand, <NUM> parts of quartz powder, <NUM> parts of water reducer, <NUM> parts of water, and <NUM> parts of toughening agent.

Specifically, the quartz sand has a fineness modulus of <NUM> (the fineness modulus of the quartz sand may be <NUM>-<NUM>, and the present embodiment selects to use <NUM>), a content of silicon dioxide above <NUM>% and a hardness of a raw stone above <NUM>, and is free of impurities and weathering.

The quartz powder has a fineness of more than <NUM> mesh, a content of silicon dioxide above <NUM>% and a hardness of a raw stone above <NUM>.

The inorganic active powder is mainly composed of P. <NUM> white cement doped with white silicon powder. However, it should be appreciated that one or more active powders selected from the group consisting of, mineral powder, nano calcium oxide, nano silicon oxide and sintered high white kaolin powder can be doped.

The pigment is inorganic pigments of various colors.

The water reducer does not have a metal ion color, the concentration of the water reducer is no more than <NUM>%, the water reduction rate of the water reducer is more than <NUM>%, and the retarding time is <NUM>-<NUM> hour.

The sand is river sand which excludes mud, mud block and organic shellfish, and has material firmness quality loss of not greater than <NUM>%, a maximum particle diameter of not greater than <NUM> and a fineness modulus of <NUM>. However, the sand can be one or more selected from the group consisting of river sand, manufactured sand, and quartz sand.

The metal fiber has a diameter of <NUM>, an aspect ratio of <NUM> and a tensile strength of greater than <NUM> MPa. However, the mental fiber may be one or more of metal fibers having a diameter range of <NUM>-<NUM>, an aspect ratio of <NUM>-<NUM> and a tensile strength of greater than <NUM> MPa.

The toughening agent is polyvinyl alcohol glue and acrylamide glue.

The high toughness inorganic composite artificial stone panel is manufactured according to the following steps:.

Except that the formula of the high toughness inorganic composite artificial stone panel is different, other conditions are the same as those in Embodiment <NUM>.

A high toughness inorganic composite artificial stone panel includes: a surface layer including the following raw material components in parts by weight: <NUM> parts of quartz sand, <NUM> parts of quartz powder, <NUM> parts of inorganic active powder, <NUM> parts of pigment, <NUM> part of water reducer and <NUM> parts of water; an intermediate metal fiber toughening layer including the following raw material components in parts by weight: <NUM> parts of inorganic active powder, <NUM> parts of sand, <NUM> parts of water reducer, <NUM> parts of water and <NUM> parts of metal fiber; and a substrate toughening layer including the following raw material components in parts by weight: <NUM> parts of inorganic active powder, <NUM> parts of quartz sand, <NUM> parts of quartz powder, <NUM> parts of water reducer, <NUM> parts of water and <NUM> parts of toughening agent.

A high toughness inorganic composite artificial stone panel includes: a surface layer including the following raw material components in parts by weight: <NUM> parts of quartz sand, <NUM> parts of quartz powder, <NUM> parts of inorganic active powder, <NUM> parts of pigment, <NUM> part of water reducer and <NUM> parts of water; an intermediate metal fiber toughening layer including the following raw material components in parts by weight: <NUM> parts of inorganic active powder, <NUM> parts of sand, <NUM> part of water reducer, <NUM> parts of water and <NUM> parts of metal fiber; and a substrate toughening layer including the following raw material components in parts by weight: <NUM> parts of inorganic active powder, <NUM> parts of quartz sand, <NUM> parts of quartz powder, <NUM> part of water reducer, <NUM> parts of water and <NUM> parts of toughening agent.

A high toughness inorganic composite artificial stone panel includes: a surface layer including the following raw material components in parts by weight: <NUM> parts of quartz sand, <NUM> parts of quartz powder, <NUM> parts of inorganic active powder, <NUM> parts of pigment, <NUM> parts of water reducer and <NUM> parts of water; an intermediate metal fiber toughening layer including the following raw material components in parts by weight: <NUM> parts of inorganic active powder, <NUM> parts of sand, <NUM> part of water reducer, <NUM> parts of water and <NUM> parts of metal fiber; and a substrate toughening layer including the following raw material components in parts by weight: <NUM> parts of inorganic active powder, <NUM> parts of quartz sand, <NUM> parts of quartz powder, <NUM> parts of water reducer, <NUM> parts of water and <NUM> parts of toughening agent.

Except that the substrate layer does not contain toughening agent, others are the same as those in Embodiment <NUM>.

Except that the intermediate toughening layer does not contain metal fiber, others are the same as those in Embodiment <NUM>.

The high toughness inorganic composite artificial stone panels prepared in the above Embodiments <NUM>-<NUM> and Comparative Examples <NUM>-<NUM> are manufactured as standard sample to perform performance tests. Test results are shown in Table <NUM>:.

Claim 1:
A high toughness inorganic composite artificial stone panel, comprising: a surface layer (<NUM>), an intermediate metal fiber toughening layer (<NUM>), and a substrate toughening layer (<NUM>);
wherein the surface layer (<NUM>) comprises the following raw material components in parts by weight: <NUM>-<NUM> parts of quartz sand, <NUM>-<NUM> parts of quartz powder, <NUM>-<NUM> parts of inorganic active powder, <NUM>-<NUM> parts of pigment, <NUM>-<NUM> part of water reducer and <NUM>-<NUM> parts of water;
the intermediate metal fiber toughening layer (<NUM>) comprises the following raw material components in parts by weight: <NUM>-<NUM> parts of inorganic active powder, <NUM>-<NUM> parts of sand, <NUM>-<NUM> parts of water reducer, <NUM>-<NUM> parts of water and <NUM>-<NUM> parts of metal fiber; and
the substrate toughening layer (<NUM>) comprises the following raw material components in parts by weight: <NUM>-<NUM> parts of inorganic active powder, <NUM>-<NUM> parts of quartz sand, <NUM>-<NUM> parts of quartz powder, <NUM>-<NUM> parts of water reducer, <NUM>-<NUM> parts of water and <NUM>-<NUM> parts of toughening agent,
wherein the quartz sand has a fineness modulus of <NUM>-<NUM>, a content of silicon dioxide above <NUM>% and a hardness of a raw stone above <NUM> Mohs; and
the quartz powder has a fineness of <NUM> mesh or more, a content of silicon dioxide above <NUM>%, a hardness of a raw stone above <NUM> Mohs.