U.S. patent application number 16/600561 was filed with the patent office on 2021-01-14 for composite plate and preparation method thereof.
The applicant listed for this patent is FOSHAN YIXIN STONE CO., LTD. Invention is credited to Zhijian Liang, Junxian Liu, Ting Liu, Jiansong Xian, Guoming Zhang.
Application Number | 20210009466 16/600561 |
Document ID | / |
Family ID | 1000004437058 |
Filed Date | 2021-01-14 |
![](/patent/app/20210009466/US20210009466A1-20210114-P00001.png)
United States Patent
Application |
20210009466 |
Kind Code |
A1 |
Zhang; Guoming ; et
al. |
January 14, 2021 |
COMPOSITE PLATE AND PREPARATION METHOD THEREOF
Abstract
A composite plate is mainly made from the following raw
materials in percentage by weight: 35% to 45% of calcium carbonate,
45% to 55% of cullet, 5% to 15% of unsaturated polyester resin,
0.1% to 1% of a curing agent, 0.1% to 1% of an auxiliary agent,
wherein a ratio of an amount of the calcium carbonate to an amount
of the cullet is 0.75%. The invention employs cullet, calcium
carbonate, and resin as the main raw materials to prepare an
artificial stone plate; no natural quartz is used, and hence the
raw material cost is low. A reasonable ratio of cullet to calcium
carbonate reduces the use of resin, which further reduces the raw
material cost. Through a reasonable combination of different raw
materials, the composite plate of the invention has physical and
chemical properties and decorative abilities that are similar to
those of traditional artificial quartz stone.
Inventors: |
Zhang; Guoming; (Foshan,
CN) ; Xian; Jiansong; (Foshan, CN) ; Liang;
Zhijian; (Foshan, CN) ; Liu; Junxian; (Foshan,
CN) ; Liu; Ting; (Foshan, CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FOSHAN YIXIN STONE CO., LTD |
Foshan |
|
CN |
|
|
Family ID: |
1000004437058 |
Appl. No.: |
16/600561 |
Filed: |
October 13, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C03C 2214/12 20130101;
C03C 14/004 20130101; C03C 1/002 20130101; C03C 2214/04 20130101;
C03C 2214/30 20130101 |
International
Class: |
C03C 14/00 20060101
C03C014/00; C03C 1/00 20060101 C03C001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 8, 2019 |
CN |
201910607431.7 |
Claims
1. A composite plate, wherein it is mainly made from the following
raw materials in percentage by weight: 35% to 45% of calcium
carbonate, 45% to 55% of cullet, 5% to 15% of unsaturated polyester
resin, 0.1% to 1% of a curing agent, 0.1% to 1% of an auxiliary
agent, wherein a ratio of an amount of the calcium carbonate to an
amount of the cullet is 0.75%.
2. The composite plate according to claim 1, wherein it is mainly
made from the following raw materials in percentage by weight: 39%
to 45% of calcium carbonate, 45% to 53% of cullet, 5% to 9% of
unsaturated polyester resin, 0.6% to 1% of a curing agent, 0.5% to
0.9% of an auxiliary agent.
3. The composite plate according to claim 2, wherein it is made
from the following raw materials in percentage by weight: 40% of
calcium carbonate, 50% of cullet, 8.7% of unsaturated polyester
resin, 0.7% of a curing agent, 0.6% of an auxiliary agent.
4. The composite plate according to claim 1, wherein the calcium
carbonate has a particle size of 280 to 400 mesh; the cullet has a
particle size of 40 to 150 mesh.
5. The composite plate according to claim 4, wherein the calcium
carbonate has a particle size of 300 to 350 mesh; the cullet has a
particle size of 40 to 120 mesh.
6. The composite plate according to claim 5, wherein the cullet
comprises a first cullet and a second cullet, the first cullet has
a particle size of 40 to 70 mesh, the second cullet has a particle
size of 70 to 120 mesh; an amount of the first cullet:an amount of
the second cullet=(0.5-1.5):(1-2).
7. The composite plate according to claim 1, wherein the
unsaturated polyester resin is a linear polymer compound having an
ester bond and an unsaturated double bond formed by
polycondensation of an unsaturated dibasic acid and a diol or
polycondensation of a saturated dibasic acid and an unsaturated
diol.
8. The composite plate according to claim 1, wherein the curing
agent is one or more selected from the group consisting of t-butyl
peroxy-2-ethylhexanoate, t-butyl peroxybenzoate, and benzoyl
peroxide; the auxiliary agent is one or more selected from the
group consisting of a silane coupling agent, an aluminate coupling
agent, and a titanate coupling agent.
9. The composite plate according to claim 8, wherein, wherein the
curing agent is t-butyl peroxy-2-ethylhexanoate; the auxiliary
agent is .gamma.-methacryloxypropyltrimethoxysilane.
10. A preparation method of the composite plate according to claim
1, wherein it comprises the following steps: (1) preparing each raw
material according to a formula; (2) mixing various raw materials
thoroughly to obtain a base material; (3) subjecting the base
material to vibration pressing to obtain a plate clay body; (4)
heat-curing the plate clay body at 80-120.degree. C. to obtain the
composite plate.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of Chinese Patent
Application No. 201910607431.7 filed on Jul. 8, 2019, the contents
of which are incorporated herein by reference in their
entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to the technical field of
construction materials, in particular to a composition plate and a
preparation method thereof.
BACKGROUND OF THE INVENTION
[0003] With the continuous improvement of living standards, people
pursue a higher quality of life, and various artificial stones are
being widely used. In terms of preparation methods, existing
artificial stones can be divided into three types: a sintered type,
a heat-curing type, and a low-temperature curing type. The
preparation of the sintered type is similar to the preparation of
ceramic bricks, that is, it is obtained by firing at a high
temperature; the cost of the stone plates obtained this way is
high. The plate obtained by low-temperature curing mainly refers to
a plate using cement as the curing agent; such a plate is mostly
cured at a low temperature. The heat-curing type mainly refers to a
plate obtained by using resin as a binder, mixing quartz, calcium
carbonate, talc, feldspar, etc., and curing at 100-300.degree. C.
The plates of the heat-curing type are visually appealing and have
great decorative abilities. Therefore, existing plates are mostly
of the heat-curing type (or resin type).
[0004] The most commonly used artificial stone plates are quartz
stone plates and artificial granite (calcium carbonate plus resin).
Although artificial granite is inexpensive, it has poor chemical
resistance, thus its application is limited. On the other hand, the
artificial quartz stone has excellent mechanical properties and
chemical resistance, thus is widely used. Artificial quartz stones
are generally made from quartz stones, resin, a coupling agent, a
curing agent and the like of different particle sizes. However, due
to the gradual depletion of natural high-quality quartz, some
researchers have introduced glass into the formula to replace part
of the quartz. For example, Chinese patent CN109020302A discloses a
method for producing an artificial stone using resin, glass,
quartz, and a pigment. The proportion of glass in the formula is
larger than that of quartz. However, due to the amorphous nature of
glass, the pulverization of the glass results in a material that
has a lot of corners and edges and has a large specific surface
area, resulting in poor fluidity, thus more resin is required
compared with using quartz. In the aforementioned patent, the
amount of resin is 8%-16%, which increases the cost of the
artificial stone. The excessively high resin content also reduces
the mechanical properties of the artificial stone. Established
thinking of the person skilled in the art is that the addition of
cullet greatly reduces the fluidity of the slurry, hence the plate
is not uniform, its physical and chemical properties are also
reduced. Therefore, generally, a small amount of cullet having a
small particle size (<400 mesh) is used as a filler, or a small
amount of cullet having a large particle size (>30 mesh) is used
for decoration. Cullet is rarely used to replace quartz as a
construction aggregate (The replacement rate in the prior art is
below 50%).
[0005] Attempts have also been made to introduce calcium carbonate
powder into a quartz stone plate system. For example, Chinese
patent CN108892416A discloses a quartz stone plate, which
incorporates 10% to 13% of heavy calcium carbonate into its
formula. However, heavy calcium carbonate is not hard, thus it
reduces the mechanical properties of quartz stone plates. Another
example is Chinese patent CN107555843A, which discloses an
artificial quartz stone plate prepared using quartz, glass, calcium
carbonate, and resin. However, it uses a combination of a variety
of resins and the cost is thus high.
[0006] Summarizing the aforementioned prior art documents, there
are several problems in artificial quartz stones of the prior art:
1. A significant amount resin is used, resulting in poor mechanical
properties and high cost. 2. Quartz is used in abundance, resulting
in high raw material cost. 3. Too many different types of raw
materials give rise to a lot of early-stage processing steps and
high manufacturing cost.
SUMMARY OF THE INVENTION
[0007] The objective of the present invention is to provide a
composite plate which has low raw material cost, low preparation
cost, excellent physical and chemical properties, outstanding
decorative abilities, and is energy efficient and environmentally
friendly.
[0008] Another objective of the present invention is to provide a
method for preparing the aforementioned composite plate.
[0009] To achieve the objective above, the present invention
provides a composite plate which is mainly made from the following
raw materials in percentage by weight: 35% to 45% of calcium
carbonate, 45% to 55% of cullet, 5% to 15% of unsaturated polyester
resin, 0.1% to 1% of a curing agent, 0.1% to 1% of an auxiliary
agent;
[0010] wherein a ratio of an amount of the calcium carbonate to an
amount of the cullet is 0.75%.
[0011] As an improvement to the technical solution above, the
composite plate is mainly made from the following raw materials in
percentage by weight: 39% to 45% of calcium carbonate, 45% to 53%
of cullet, 5% to 9% of unsaturated polyester resin, 0.6% to 1% of a
curing agent, 0.5% to 0.9% of an auxiliary agent.
[0012] As an improvement to the technical solution above, the
composite plate is made from the following raw materials in
percentage by weight: 40% of calcium carbonate, 50% of cullet, 8.7%
of unsaturated polyester resin, 0.7% of a curing agent, 0.6% of an
auxiliary agent.
[0013] As an improvement to the technical solution above, the
calcium carbonate has a particle size of 280 to 400 mesh; the
cullet has a particle size of 40 to 150 mesh.
[0014] As an improvement to the technical solution above, the
calcium carbonate has a particle size of 300 to 350 mesh; the
cullet has a particle size of 40 to 120 mesh.
[0015] As an improvement to the technical solution above, the
cullet comprises a first cullet and a second cullet, the first
cullet has a particle size of 40 to 70 mesh, the second cullet has
a particle size of 70 to 120 mesh;
[0016] an amount of the first cullet:an amount of the second
cullet=(0.5-1.5):(1-2).
[0017] As an improvement to the technical solution above, the
unsaturated polyester resin is a linear polymer compound having an
ester bond and an unsaturated double bond formed by
polycondensation of an unsaturated dibasic acid and a diol or
polycondensation of a saturated dibasic acid and an unsaturated
diol.
[0018] As an improvement to the technical solution above, the
curing agent is one or more selected from the group consisting of
t-butyl peroxy-2-ethylhexanoate, t-butyl peroxybenzoate, and
benzoyl peroxide;
[0019] the auxiliary agent is one or more selected from the group
consisting of a silane coupling agent, an aluminate coupling agent,
and a titanate coupling agent.
[0020] As an improvement to the technical solution above, the
curing agent is t-butyl peroxy-2-ethylhexanoate; the auxiliary
agent is .gamma.-methacryloxypropyltrimethoxysilane.
[0021] Accordingly, the present invention provides a preparation
method of the aforementioned composite plate, wherein it comprises
the following steps:
[0022] (1) preparing each raw material according to a formula;
[0023] (2) mixing various raw materials thoroughly to obtain a base
material;
[0024] (3) subjecting the base material to vibration pressing to
obtain a plate clay body;
[0025] (4) heat-curing the plate clay body at 80-120.degree. C. to
obtain the composite plate.
[0026] The present invention has the following beneficial
effects:
[0027] 1. The invention employs cullet, calcium carbonate, and
resin as the main raw materials to prepare an artificial stone
plate; no natural quartz is used, and hence the raw material cost
is low. A reasonable ratio of cullet to calcium carbonate reduces
the use of resin, which further reduces the raw material cost.
[0028] 2. Through a reasonable combination of different particle
sizes of cullet, calcium carbonate, and resin, the composite plate
of the present invention has good physical and chemical properties.
As a result, the chemical and corrosion resistance and the
mechanical properties of the composite plate are similar to those
of the artificial quartz stones of the prior art.
[0029] 3. The invention reduces the vibration frequency of the
pressure plate during the vibration pressing process through a
combination of different particle sizes of cullet and calcium
carbonate. This leads to reduced molding time and increased
production efficiency.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS
[0030] To clearly illustrate the objectives, technical solutions
and advantageous effects of the present invention, the present
invention will be further described below.
[0031] A conventional quartz stone plate is made from a large
amount of quartz, which leads to high raw material cost. In
addition, because natural quartz often contains holes resulted from
weathering, a large amount of resin is required, which further
increases the raw material cost. Although a small amount of cullet
can be used instead of quartz to reduce the amount of quartz, the
random-occurring fracture surfaces and a large specific surface
area of the cullet require an increased amount of resin, resulting
in increased cost. Thus, the present invention provides a composite
plate which is mainly made from the following raw materials in
percentage by weight: 35% to 45% of calcium carbonate, 45% to 55%
of cullet, 5% to 15% of unsaturated polyester resin, 0.1% to 1% of
a curing agent, 0.1% to 1% of an auxiliary agent, wherein the ratio
of the amount of the calcium carbonate to the amount of the cullet
is 0.75%. The present invention does not include quartz in its raw
materials; instead, cullet is the main construction aggregate,
which greatly reduces the cost of raw materials. Besides, by adding
calcium carbonate and controlling the ratio of the amount of
calcium carbonate to the amount of cullet, the amount of resin is
effectively reduced, further reducing raw material cost. In
addition, mixing calcium carbonate and cullet gives rise to a
higher packing density, which reduces the subsequent vibration
pressing time, lowers manufacturing cost, and improves various
qualities of the product.
[0032] The cullet is obtained by crushing waste glass. The waste
glass may be selected from one or more of common soda-lime glass,
borate glass, lead silicate glass, and quartz glass. Preferably,
common soda-lime glass is used. Soda-lime glass has poor rigidity
and requires low energy to crush. After it is crushed, its specific
surface area is relatively small, which reduces the amount of resin
required and increases the strength of the composite plate. In
addition, the replacement of quartz by cullet allows the recycling
of waste glass.
[0033] 45-55 wt % of the cullet is added. When the amount of quartz
exceeds 55 wt %, the amount of calcium carbonate decreases, and
calcium carbonate is unable to fully provide desirable fluidity. As
a result, the clay body of the plate is not homogenous, and its
physical and chemical properties are lowered; in addition, the
amount of resin used is increased, leading to increased cost. When
the amount of quartz is <45 wt %, the amount of calcium
carbonate increases, which significantly reduces the mechanical
properties and chemical resistance of the composite plate.
Preferably, 45-53 wt % of the cullet is added; preferably 50 wt %
of the cullet is added.
[0034] Further, to balance the raw material cost, the manufacturing
cost, and the physical and chemical properties, the present
invention controls the particle size of the cullet to be 40 to 150
mesh. The cullet within this particle size range can function as a
construction aggregate and can improve the physical and chemical
properties of the composite plate. Also, the amount of resin
adsorbed by the cullet within this particle size range is small and
the fluidity is moderate. In addition, compared with quartz
materials, the cullet of such a particle size produces a composite
plate that is more transparent, and the effect of pigment and the
like is more apparent, which greatly improves the decorative
effects of the composite plate.
[0035] Preferably, the cullet has a particle size of 40 to 120
mesh. More preferably, the cullet comprises a first cullet and a
second cullet. The first cullet has a particle size of 40 to 70
mesh, the second cullet has a particle size of 70 to 120 mesh. The
amount of the first cullet: the amount of the second
cullet=(0.5-1.5):(1-2); the cullet mixture having this ratio has
better fluidity and allows good mechanical properties. More
preferably, the amount of the first cullet: the amount of the
second cullet=1:1. More preferably, the first cullet has a particle
size of 50 mesh, the second cullet has a particle size of 100 mesh,
and the amount of the first cullet: the amount of the second
cullet=1:1.
[0036] Calcium carbonate is heavy calcium carbonate or light
calcium carbonate. Alternatively, calcium carbonate is selected
from activated calcium carbonate or crystalline calcium carbonate,
but is not limited thereto. The amount of resin adsorbed by the
calcium carbonate material is small, and can effectively increase
the bulk density of the mixed raw materials, improving
fluidity.
[0037] Calcium carbonate is added in a weight percentage of 35% to
45%, the amount of calcium carbonate: the amount of cullet 0.75.
Preferably, calcium carbonate is added in a weight percentage of
39% to 45%, and the amount of calcium carbonate: the amount of
cullet is 0.75 to 0.9. Controlling the amount of calcium carbonate
and cullet effectively give rise to better mechanical properties,
decorative abilities, and lower raw material costs and
manufacturing costs.
[0038] Further, in order to fully exert the effects of calcium
carbonate, the particle size of the calcium carbonate is 280-400
mesh. It should be noted that in the pressing process, the flow
distance of coarse cullet is small, thus it is difficult to
homogenize and level. The usual approach is to increase the amount
of resin, but the cost is high. The present invention uses a fine
calcium carbonate, which can flow and fill during the pressing
process, and is able to improve the density and mechanical
properties of the composite plate while reducing the amount of the
resin. Preferably, the calcium carbonate has a particle size of 300
to 350 mesh.
[0039] The unsaturated polyester resin is a linear polymer compound
having an ester bond and an unsaturated double bond formed by the
polycondensation of an unsaturated dibasic acid and a diol or the
polycondensation of a saturated dibasic acid and an unsaturated
diol. The curing agent is one or more selected from the group
consisting of t-butyl peroxy-2-ethylhexanoate, t-butyl
peroxybenzoate, and benzoyl peroxide. The auxiliary agent is one or
more selected from the group consisting of a silane coupling agent,
an aluminate coupling agent, and a titanate coupling agent.
[0040] Preferably, the curing agent is t-butyl
peroxy-2-ethylhexanoate, the auxiliary agent is
.gamma.-methacryloxypropyltrimethoxysilane.
[0041] The unsaturated polyester resin is added in an amount of 5
wt % to 15 wt %, preferably 5 wt % to 9 wt %. The curing agent is
added in an amount of 0.1 wt % to 1 wt %, preferably 0.6 wt % to 1
wt %. The auxiliary agent is added in an amount of 0.1 wt % to 1 wt
%, preferably 0.5 wt % to 0.9 wt %.
[0042] Further, the raw material of the composite plate of the
present invention comprises a pigment. The pigment may be selected
from one or two kinds of an inorganic pigment and an organic
pigment. The pigment is 0% to 2% of the total raw material
weight.
[0043] Accordingly, the present invention also discloses a method
for preparing the aforementioned composite plate, which comprises
the following steps:
[0044] I. Preparing each raw material according to a formula.
[0045] Specifically, each raw material is prepared according to a
formula, and the raw materials are pre-processed so that their
particle sizes are within the range required by the present
invention.
[0046] II. Mixing the various raw materials thoroughly to obtain a
base material.
[0047] Specifically, first, a resin, a curing agent, and an
auxiliary agent are thoroughly mixed to obtain a slurry; then,
cullet and calcium carbonate are added to the slurry, and the
mixture is thoroughly mixed to obtain the base material.
[0048] Preferably, the method further comprises mixing a part of
the resin with a pigment to obtain a decorative material.
[0049] III. Subjecting the base material to vibration pressing to
obtain a plate clay body.
[0050] Specifically, the method comprises uniformly distributing
the base material on a mold to obtain stacked powder; filling the
decorative material into the stacked powder according to a
predetermined pattern; and then performing vibration pressing to
obtain the plate clay body; or
[0051] mixing the base material and decorative material to obtain a
mixture; distributing the mixture on a mold; performing vibration
pressing to obtain the plate clay body.
[0052] The frequency of vibration pressing is 30 Hz to 60 Hz and
the vibration pressing time is 2 min to 5 min. Preferably, the
frequency of vibration pressing is 30 Hz to 50 Hz, the vibration
pressing time is 1 min to 3 min. The invention increases the bulk
density and fluidity of the mixture through its composition, which
leads to shortened pressing time and increased production
efficiency.
[0053] IV. Heat-curing the plate clay body at 80-120.degree. C. to
obtain the composite plate.
[0054] The preparation method further comprises processes of
thickness gauging, polishing, and cutting of the composite
plate.
[0055] The invention will now be described with reference to
specific embodiments.
Embodiment 1
[0056] This embodiment provides a composite plate prepared from the
following formula:
[0057] 45% cullet, 38% calcium carbonate, 15% unsaturated polyester
resin, 1% curing agent, 1% auxiliary agent;
[0058] wherein the curing agent is t-butyl peroxybenzoate and the
auxiliary agent is a titanate coupling agent.
[0059] The cullet has a particle size ranging from 130 to 150 mesh,
the calcium carbonate has a particle size ranging from 280 to 300
mesh.
[0060] Preparation:
[0061] (1) Each raw material was prepared according to the
formula.
[0062] (2) Various raw materials were mixed uniformly to obtain a
base material.
[0063] (3) The base material was subjected to vibration pressing to
obtain a plate clay body, wherein the vibration pressing frequency
was 30 Hz, the time was 5 min.
[0064] (4) The plate clay body was heat-cured at 80.degree. C. to
obtain the composite plate product.
Embodiment 2
[0065] This embodiment provides a composite plate prepared from the
following formula:
[0066] 49.8% cullet, 45% calcium carbonate, 5% unsaturated
polyester resin, 0.1% curing agent, 0.1% auxiliary agent;
[0067] wherein the curing agent is benzoyl peroxide and the
auxiliary agent is an aluminate coupling agent.
[0068] The cullet has a particle size ranging from 40 to 50 mesh,
the calcium carbonate has a particle size ranging from 380 to 400
mesh.
[0069] Preparation:
[0070] (1) Each raw material was prepared according to the
formula.
[0071] (2) Various raw materials were mixed uniformly to obtain a
base material.
[0072] (3) The base material was subjected to vibration pressing to
obtain a plate clay body, wherein the vibration pressing frequency
was 40 Hz, the time was 2 min.
[0073] (4) The plate clay body was heat-cured at 90.degree. C. to
obtain the composite plate product.
Embodiment 3
[0074] This embodiment provides a composite plate prepared from the
following formula:
[0075] 51% cullet, 41.8% calcium carbonate, 6% unsaturated
polyester resin, 0.7% curing agent, 0.5% auxiliary agent;
[0076] wherein the curing agent is t-butyl peroxy-2-ethylhexanoate
and the auxiliary agent is
.gamma.-methacryloxypropyltrimethoxysilane.
[0077] The cullet has a particle size ranging from 100 to 120 mesh,
the calcium carbonate has a particle size ranging from 300 to 320
mesh.
[0078] Preparation:
[0079] (1) Each raw material was prepared according to the
formula.
[0080] (2) Various raw materials were mixed uniformly to obtain a
base material.
[0081] (3) The base material was subjected to vibration pressing to
obtain a plate clay body, wherein the vibration pressing frequency
was 45 Hz, the time was 2 min.
[0082] (4) The plate clay body was heat-cured at 90.degree. C. to
obtain the composite plate product.
Embodiment 4
[0083] This embodiment provides a composite plate prepared from the
following formula:
[0084] 50% cullet, 43.2% calcium carbonate, 5.1% unsaturated
polyester resin, 0.8% curing agent, 0.9% auxiliary agent;
[0085] wherein the curing agent is t-butyl peroxy-2-ethylhexanoate
and the auxiliary agent is
.gamma.-methacryloxypropyltrimethoxysilane.
[0086] The cullet has a particle size ranging from 40 to 60 mesh,
the calcium carbonate has a particle size ranging from 320 to 350
mesh.
[0087] Preparation:
[0088] (1) Each raw material was prepared according to the
formula.
[0089] (2) Various raw materials were mixed uniformly to obtain a
base material.
[0090] (3) The base material was subjected to vibration pressing to
obtain a plate clay body, wherein the vibration pressing frequency
was 45 Hz, the time was 2 min.
[0091] (4) The plate clay body was heat-cured at 90.degree. C. to
obtain the composite plate product.
Embodiment 5
[0092] This embodiment provides a composite plate prepared from the
following formula:
[0093] 50% cullet, 40% calcium carbonate, 8.7% unsaturated
polyester resin, 0.7% curing agent, 0.6% auxiliary agent;
[0094] wherein the curing agent is t-butyl peroxy-2-ethylhexanoate
and the auxiliary agent is
.gamma.-methacryloxypropyltrimethoxysilane.
[0095] The cullet has a particle size ranging from 40 to 60 mesh,
the calcium carbonate has a particle size ranging from 320 to 350
mesh.
[0096] The preparation method is the same as that of embodiment
4.
Embodiment 6
[0097] This embodiment provides a composite plate prepared from the
same formula as that of embodiment 4 via a method that is the same
as that of embodiment 4.
[0098] The main differences are that the cullet includes 25% of a
first cullet and 25% of a second cullet. The particle size of the
first cullet is 40-60 mesh, the particle size of the second cullet
is 80-100 mesh.
[0099] The particle size of calcium carbonate is 340-350 mesh.
Comparative Embodiment 1
[0100] This embodiment provides an artificial quartz stone prepared
from the following formula:
[0101] 62.6% cullet, 20% quartz, 17% resin, 0.2% curing agent, 0.2%
auxiliary agent;
[0102] wherein the cullet includes 15% of a first cullet, 25% of a
second cullet, and 22.6% of a third cullet. The first cullet has a
particle size of 1-10 mesh; the second cullet has a particle size
of 325-600 mesh; the third cullet has a particle size of 40-120
mesh. The particle size of quartz is 40-120 mesh.
[0103] Preparation:
[0104] (1) Each raw material was prepared according to the
formula.
[0105] (2) Various raw materials were mixed uniformly to obtain a
base material.
[0106] (3) The base material was subjected to vibration pressing to
obtain a plate clay body, wherein the vibration pressing frequency
was 45 Hz, the time was 4 min.
[0107] (4) The plate clay body was heat-cured at 92.degree. C. to
obtain the artificial quartz stone product.
Comparative Embodiment 2
[0108] This embodiment provides an artificial quartz stone prepared
from the following formula:
[0109] 71.5% quartz, 15% calcium carbonate, 9% unsaturated
polyester resin, 2.5% curing agent, 2% coupling agent (an auxiliary
agent);
[0110] wherein the quartz includes 45% of a first quartz and 16.5%
of a second quartz. The first quartz has a particle size of 60-100
mesh; the second quartz has a particle size of 280-300 mesh.
[0111] Embodiments 1-6 and comparative embodiments 1-2 were tested
according to the method specified in Chinese standard JC/T908-2013,
the results are as follows.
TABLE-US-00001 Compres- Total Bending sive stain strength/
strength/ resis- Chemical Appear- MPa MPa Gloss tance resistance
ance Embodi- 44.3 188 43 55 Resistant Uniform ment 1 color, smooth
Embodi- 45.8 184.4 42 54 Resistant Uniform ment 2 color, smooth
Embodi- 45.7 198 43 54 Resistant Uniform ment 3 color, smooth
Embodi- 47.3 196 42 56 Resistant Uniform ment 4 color, smooth
Embodi- 49 200 44 55 Resistant Uniform ment 5 color, smooth Embodi-
50.6 208 46 58 Resistant Uniform ment 6 color, smooth Compar- 52.4
216 38 56 Resistant Uniform ative color, embodi- smooth ment 1
Compar- 45.2 176 33 56 Resistant Uniform ative color, embodi-
smooth ment 2
[0112] The above are only the preferred embodiments of the present
invention, and the scope of the present invention is not limited
thereto. Improvements and modifications made according to the
claims of the present invention are still within the scope of the
present invention.
* * * * *