CN112315357B

CN112315357B - Artificial bathroom deck and preparation method thereof

Info

Publication number: CN112315357B
Application number: CN202011196529.7A
Authority: CN
Inventors: 彭秧锡; 陈占军; 阳湘琳; 卢玉厚; 杨威; 陈金鹰; 彭嘉妮; 颜震宇
Original assignee: Hunan University of Humanities Science and Technology
Current assignee: Hunan University of Humanities Science and Technology
Priority date: 2020-10-31
Filing date: 2020-10-31
Publication date: 2022-12-09
Anticipated expiration: 2040-10-31
Also published as: CN112315357A

Abstract

The invention relates to an artificial bathroom deck plate, which comprises a cement substrate, wherein the cement substrate is formed by integrally pouring cement slurry; the cement paste comprises the following components in percentage by mass: 20-60% of cement, 30-70% of quartz sand, 0.1-10% of micro-beads, 0.01-2% of a water reducing agent, 0.01-2% of lithium carbonate, 0.01-2% of sodium gluconate, 0.01-2% of glass fibers and 0.1-6% of low-temperature water-based emulsion; adding water into the materials of the components and mixing to obtain cement paste; the cement paste has a water-to-cement ratio of 0.25-0.5 and a cement-to-sand ratio of 0.25-0.7. The cement substrate adopts an innovative cement paste formula, can provide sufficient breaking strength and compressive strength under the condition of extremely thin thickness after being cured, is suitable for manufacturing bathroom furniture with light weight and convenient carrying, and has the advantages of falling resistance, durability, fire resistance, acid-base corrosion resistance, sewage permeation resistance and the like. In the preparation process, the addition amounts of the sodium gluconate, the lithium carbonate, the microbeads, the water reducing agent and the like are regulated and controlled, so that the early strength of the concrete is enhanced, the setting time is shortened, the later strength is not lost, the demoulding can be carried out only by curing for 1-3 hours, and the production efficiency is improved.

Description

Artificial bathroom deck and preparation method thereof

Technical Field

The invention relates to the technical field of inorganic building boards, in particular to an artificial bathroom counter top board and a preparation method thereof.

Background

The bathroom is a product such as a washbasin, a washing table and the like in the bathroom, and the table top is usually made of natural marble or ceramic at present. Ceramics are easy to clean but are brittle, which is a disadvantage of ceramics. In addition, the natural stone is widely and commonly used by people to make the table-board of products such as bathroom, etc., especially the table-board of some high-grade hotels or hotels which use marble as wash basin, and the defects are as follows: the material is scarce, the cost is high, the material can not be regenerated, the processing is difficult, the natural resources are damaged, and the environment is not protected. Natural stone also has problems of being extremely heavy and difficult to handle. The artificial stone has wide raw materials, convenient and beautiful modeling and low production cost, and gradually enters the family decoration industry along with the development of social economy, and particularly has wide application in the aspects of bathrooms and the like, such as: decorative plates for kitchen table-boards, bathroom table-boards and the like. However, the artificial bathroom table top is easy to crack in the surface during the processing process or along with the time, or suddenly suffers from pressure or bending, so that the appearance is affected, and meanwhile, dirt and bacteria are easily hidden in the cracks, so that the overall tidiness is affected. Therefore, the durability, bending resistance and compression strength of the artificial bathroom countertops are the first problems to be solved by such products. Furthermore, the individual production cycle and costs also need to be further optimized.

Disclosure of Invention

Technical problem to be solved

In view of the defects in the prior art, the invention provides the artificial bathroom deck panel and the preparation method thereof, the cement base plate is integrally cast in the mould mainly by designing and optimizing the formula of the cement slurry, so that the plate still has very strong flexural strength and compressive strength under the condition of being thin, and the bathroom deck made by taking the cement base plate as the base plate has the advantages of good durability, falling resistance, difficult occurrence of cracks, low cost, fire resistance, flame retardance and the like. In addition, by optimizing the formula of the cement paste, the cement substrate can be demoulded in a short time, and the production efficiency is improved.

(II) technical scheme

In order to achieve the purpose, the invention adopts the main technical scheme that:

in a first aspect, the invention provides an artificial bathroom deck panel, which comprises a cement substrate, wherein the cement substrate is integrally cast and formed by cement slurry; the cement paste comprises the following components in percentage by mass: 20-60% of cement, 30-70% of quartz sand, 0.1-10% of micro-beads, 0.01-2% of a water reducing agent, 0.01-2% of lithium carbonate, 0.01-2% of sodium gluconate, 0.01-2% of glass fibers and 0.1-6% of low-temperature water-based emulsion; adding water into the materials of the components and mixing to obtain cement paste; the cement paste has a water-to-cement ratio of 0.25-0.5 and a cement-to-sand ratio of 0.25-0.7.

Wherein: water-to-glue ratio: the ratio of water consumption per cubic meter of concrete to the amount of all cementitious materials (including cement, microbeads, etc.) is specified. The small water-gel ratio can cause large hydration heat, the concrete is easy to crack, the workability is poor, and the field construction operation is not facilitated. Too large a water-to-gel ratio can reduce the strength of the concrete. In the invention, the water-glue ratio is controlled between 0.25 and 0.5.

Mortar ratio = amount of cementitious material (including cement, microbeads, etc.) per amount of sand, the mortar ratio affecting the strength and workability of the concrete. In the invention, the rubber-sand ratio is controlled between 0.25 and 0.7.

Preferably, when the components are used, the initial automatic fluidity of the cement paste is 200-250mm (national test standard: GB/T2419-2005) by controlling the water-cement ratio, the mortar-sand ratio, the addition amount of the micro-beads, the water reducing agent and the like, which indicates that the cement paste has good processing performance.

Preferably, the cement is a mixture of one or more of the reference numbers 32.5, 32.5R, 42.5R, 52.5R, 62.5R.

Preferably, the quartz sand has a particle size of 0.01 to 5mm.

Preferably, the micro-beads are spherical, continuous particle size distribution, superfine fly ash aluminosilicate fine micro-beads (sinking beads), and the particle size distribution range is (d 10 is less than or equal to 0.5 mu m, d50 is less than or equal to 1.5 mu m, and d95 is less than or equal to 5 mu m).

Preferably, the water reducing agent is a polycarboxylic acid water reducing agent, and the using amount of the water reducing agent is 0.01-2%. Compared with other water reducing agents, the polycarboxylic acid high-efficiency water reducing agent has the outstanding advantages of high water reducing rate, low slump loss and the like, and the using amount of the water reducing agent is not suitable to exceed the range; the optimal amount of the polycarboxylic acid water reducing agent is reached when the amount of the polycarboxylic acid water reducing agent is 0.3 percent.

Preferably, the lithium carbonate is used in an amount of 0.01 to 2%. The lithium carbonate plays a role in increasing the early compressive strength of the bathroom deck panel in the formula. The lithium carbonate should not be used in an amount exceeding this range, and the amount is preferably 0.05%.

Wherein the dosage of the sodium gluconate is 0.01-2%. The sodium gluconate plays a role in enhancing the bending strength of the bathroom deck panel in the formula.

Preferably, the glass fibers have a diameter of 5 to 10 μm and a length of 5 to 20mm in an amount of 0.01 to 2%.

Wherein the low-temperature water-based emulsion is water-based polyurethane emulsion, water-based polyacrylic emulsion, water-based Styrene Butadiene Rubber (SBR) emulsion, water-based natural rubber emulsion, water-based rosin emulsion or water-based terpene emulsion; preferably an aqueous polyacrylic acid emulsion. (the solid content of the commercially available aqueous polyacrylic acid emulsion is about 50%) the low-temperature aqueous emulsion plays a role of a flexible binder in the formula, so that the folding strength or flexibility of the bathroom deck panel can be increased, and the thinner bathroom deck panel (such as 4 cm) has stronger folding strength and certain waterproof and moisture-proof effects. The dosage of the low-temperature water-based emulsion is 0.1-6%. The low-temperature aqueous emulsion should not exceed this range; the optimal dosage is 2.5%.

In a preferred embodiment of the invention, the bathroom deck panel comprises the cement substrate, and a nano ceramic emulsion which is coated on the surface of the cement substrate and plays a role in preventing water penetration; or the bathroom deck panel comprises the cement substrate, nano ceramic emulsion which is coated on the surface of the cement substrate and plays a role in preventing water penetration, and a decorative pattern layer on the outermost side; the decorative pattern layer is decorative paint or decorative concrete mortar. Wherein the nano ceramic emulsion contains ceramic particles with the particle size of 5-20 nanometers, and the solid content is 20-60 percent; the emulsion also contains water, dispersant, polyacrylic acid and other binding agents. The dispersing agent is PVP, PEG or the like.

In the preferred embodiment of the invention, the thickness of the bathroom table board is 10-80mm, preferably 40-60mm.

In another aspect, the present invention further provides a method for preparing an artificial bathroom deck, comprising:

s1: preparation of cement paste

Adding 20-60% of cement, 30-70% of quartz sand, 0.1-10% of micro-beads, 0.01-2% of water reducing agent, 0.01-2% of lithium carbonate, 0.01-2% of sodium gluconate, 0.01-2% of glass fiber and 0.1-6% of low-temperature water-based emulsion into water together according to the mass percentage, controlling the water-to-cement ratio to be 0.25-0.5 and the cement-to-sand ratio to be 0.25-0.7, and uniformly stirring to prepare cement paste with the initial automatic fluidity of 200-250mm;

s2: surface treatment of molds

The mould comprises a mould frame and a flat plate, and the mould frame is placed on the flat plate; before injection molding, coating inorganic nano emulsion on the inner wall of a mold frame and the surface of a flat plate; the inorganic nano emulsion is obtained by dispersing and emulsifying an inorganic nano micro powder material and a surfactant in water;

s3 injection moulding

Pouring the cement paste prepared in the step S1 into a mold frame, after vibration leveling, standing and curing for 1-3h under natural conditions, carrying out extrusion and polishing on the surface of the cement paste in the mold frame by using a polishing machine to ensure that the thickness is uniform and within a specified size, demolding, and maintaining to obtain a cement substrate;

and S4, coating a layer of nano ceramic emulsion with a waterproof and permeation-resistant effect on one side of the smooth surface of the cement substrate, and drying to obtain the artificial bathroom deck.

Wherein the low-temperature water-based emulsion is water-based polyurethane emulsion, water-based polyacrylic emulsion, water-based Styrene Butadiene Rubber (SBR) emulsion, water-based natural rubber emulsion, water-based rosin emulsion or water-based terpene emulsion; the nano ceramic emulsion contains ceramic particles with the particle size of 5-20 nanometers, and the solid content is 20-60%; the emulsion also contains water, dispersant, polyacrylic acid and other binders. The dispersing agent is PVP or PEG and the like.

Preferably, in step S2, the flat plate in the mold is one of a tempered glass plate, a wood plate, a cement plate or a metal plate with a smooth surface.

Preferably, in step S2, the inorganic nano emulsion is a silica nano emulsion, an alumina nano emulsion, a titanium oxide nano emulsion, or an iron oxide nano emulsion.

Preferably, in step S1, the preparation method of the cement slurry comprises: the preparation method comprises the steps of firstly uniformly stirring glass fibers, a polycarboxylic acid water reducing agent, cement and water, then adding quartz sand, continuously and uniformly stirring, then adding microbeads, lithium carbonate, sodium gluconate and a low-temperature water-based emulsion, and continuously and uniformly stirring to obtain cement paste.

Preferably, in the step S3, the pouring is performed twice, wherein 1/2 of the thickness of the total module is poured firstly, then a layer of glass fiber net is placed, the vibration is carried out for paving, then 1/2 of the thickness of the total module is continuously poured, and then the vibration is carried out for paving.

Preferably, the curing is performed in constant-temperature water at 40-80 ℃ for 12-48h, and the curing method is any one of the following modes:

the first method is as follows: spraying constant-temperature water at 40-80 ℃ on the surface of the cement substrate, and keeping the surface moist;

the second method comprises the following steps: forming a water vapor environment of 40-80 ℃ in the closed space, and placing the cement substrate in the closed environment.

Preferably, after the nano ceramic emulsion is coated and dried, a layer of decorative paint, baking enamel paint or decorative concrete mortar or ceramic glaze is coated on the smooth surface of the cement substrate, so that the cement substrate has aesthetic property. Preferably a ceramic glaze. The adhesive force of paint such as paint on the surface of the cement substrate is 1-2 grades. (adhesion test Standard GB 1720-1979 (1989), with level 1 being the highest standard.)

(III) advantageous effects

(1) By adjusting the formula of the cement slurry, the thickness of the artificial bathroom table board can be made very thin, for example, the impact resistance and bending strength of 4mm can reach 17MPa, and the impact resistance and bending strength of 8mm can reach 24MPa (see national standard GBT 17671-1999). Therefore, the bathroom deck plate has high breaking strength and impact strength, is resistant to falling, is not easy to crack, pit or break in the production and processing process or the use process of bathroom furniture, has very good durability, can replace the existing natural stone plate, reduces the cost of the bathroom furniture, and avoids the environmental problem caused by the exploitation of stone plates. The artificial bathroom deck plate is an inorganic plate, the fire-proof grade of the artificial bathroom deck plate reaches A1 grade, and the artificial bathroom deck plate has acid-base corrosion resistance.

(2) According to the preparation method, before injection molding, the traditional release agent is not used in the mold, but inorganic nano liquid is coated, so that the traditional release agent is prevented from remaining on the surface of a product, and the product is easy to delaminate due to poor adhesion force when being coated with decorative pattern paint or porcelain enamel paint subsequently. The invention uses nano emulsion such as nano silicon dioxide to replace the release agent, can release the paint easily without using the release agent, can maintain the paint, and can not cause the problems of poor paint pattern adhesion and the like due to residue.

In many existing processes, a layer of organic release agent is brushed between a template and cement slurry, so that the release agent remains on the surface of cement after demolding, and the bonding difficulty of the cement is increased when the cement is bonded with other substances (such as cement walls, paint and the like). In the invention, a layer of inorganic nano liquid such as silicon dioxide and the like is firstly coated on the inner wall of the die frame and dried, and the inorganic nano liquid forms a uniform, compact and flat layer of nano material on the inner wall, so that the surface tension of the nano material is enhanced, the cement slurry is not easy to interact with or wet the die frame, and the effect of easy demoulding is achieved.

(3) In the preparation process, a layer of nano ceramic emulsion with the waterproof and anti-penetrating effects is coated on the surface of the cement substrate, so that micro pores on the cement substrate can be blocked, water can be prevented from penetrating downwards into the cement substrate, an environment suitable for bacterial growth is not easily formed, and the antibacterial and anti-bacterial effects are achieved.

(4) In the preparation method, from injection molding to demolding, additives such as sodium gluconate, lithium carbonate, microbeads and a water reducing agent are regulated and controlled, so that the early strength of the concrete is enhanced, the setting time is shortened, and the later strength is not lost, therefore, demolding can be carried out after curing for 1-3 hours (optimally about 2 hours) under natural conditions (the existing cement pouring can be demolded after waiting for more than 24 hours), the manufacturing period of single products is greatly shortened, and the production efficiency is improved.

(5) The bathroom deck panel disclosed by the invention is used for a long time, and the phenomena of deformation, warping and cracking do not occur. Tests prove that for the cement base plate alone, after constant-temperature curing at 40-80 ℃, a cement plate with the thickness of 4mm is prepared, and the bending strength is measured to be 17MPa; the bending strength of 8mm is 24MPa; boiling in 100 deg.C boiled water for 6 hr, taking out, testing deformation rate less than 0.3%, and no cracking.

(6) The formula of the cement paste is not limited to manufacturing a flat cement substrate, and for a complex bathroom table panel body, the complex bathroom table panel body can be integrally cast and formed through a corresponding die without the need of later procedures such as cutting, digging and the like. Because the mould is cast integrally, the strength is high and the durability is high.

Drawings

Fig. 1 is a schematic view illustrating a process for manufacturing an artificial bathroom deck according to the present invention.

Detailed Description

For the purpose of better explaining the present invention and to facilitate understanding, the present invention will be described in detail by way of specific embodiments with reference to the accompanying drawings.

The invention relates to an artificial bathroom counter top, which comprises a cement substrate, wherein the cement substrate is formed by integrally pouring cement slurry; the cement paste comprises the following components in percentage by mass: 20-60% of cement, 30-70% of quartz sand, 0.1-10% of micro-beads, 0.01-2% of a water reducing agent, 0.01-2% of lithium carbonate, 0.01-2% of sodium gluconate, 0.01-2% of glass fibers and 0.1-6% of low-temperature water-based emulsion; adding water into the materials of the components and mixing to obtain cement paste; the cement paste has a water-to-cement ratio of 0.25-0.5 and a cement-to-sand ratio of 0.25-0.7.

Wherein, after the cement paste is mixed, the initial value of the automatic fluidity of the cement paste is 200-250mm, and the initial value is about 150-180mm after 15 minutes (the test national standard: GB/T2419-2005), which indicates that the cement paste has good processing performance.

Wherein, the cement is a mixture of one or more of the numbers 32.5, 32.5R, 42.5R, 52.5R, 62.5 and 62.5R. The consumption of the cement is 20-60%. Atypical, for example, 20%, 25%, 30%, 35%, 38%, 40%, 42%, 45%, 48%, 50%, 55%, 60%. Among them, 40% is preferable. The cement is a hydraulic cementing material, is a basic material for forming a bathroom counter panel, and can tightly solidify various components in the formula into a whole. The cement dosage is 20-60%, and the dosage of the cement should not exceed the range. Too high or too low a quantity will reduce the structural strength of the panel, the effect being optimal at 40% of the quantity.

Wherein the granularity of the quartz sand is 0.01-5mm. The amount of silica sand is 30-70%, and is atypical, for example, 30%, 32%, 35%, 38%, 40%, 42%, 45%, 50%, 53%, 55%, 57%, 60%, 62%, 65%, 70%. And more preferably 55.3%. The quartz sand constitutes the aggregate component of the cement paste and is used for forming cement concrete and enhancing various strengths of the bathroom deck panel. The usage amount of the quartz sand is 30-70 percent, and the quartz sand is not suitable to exceed the range; too high or too low of a quantity may reduce the structural strength of the panel. And the optimal effect is achieved when the dosage of the quartz sand is 55.3 percent. In the technical aspect, the concrete prepared from the aggregates such as quartz sand has higher volume stability and better durability than pure cement paste, the strength and the elastic modulus of the aggregates have important influence on the mechanical property of the concrete, and when the addition amount of the cement or the quartz sand exceeds the range, the compressive strength and the flexural strength can be obviously reduced. In terms of cost, the quartz sand is much cheaper than cement, and is used as a cheap filling material for concrete, so that the manufacturing cost of the cement material is reduced. The too fine granularity of the quartz sand can cause the reduction of the fluidity of the mortar, the too coarse granularity can increase the material-sand ratio, and the both can cause the reduction of the mechanical property of the concrete.

Wherein, the dosage of the micro-bead is 0.1 to 10 percent. Atypical, for example, 0.1%, 0.5%, 1.0%, 1.5%, 2%, 2.5%, 3%, 3.5%, 4%, 4.5%, 5.0%, 5.5%, 6.0%, 7.0%, 8.0%, 9.0%, 10.0%. And more preferably 1.5%. The micro-beads play a role in increasing the fluidity of the slurry in the formula, the workability of the cement slurry is improved, the material of each part of the bathroom deck plate of the prepared bathroom deck plate has high uniformity, the spherical shape can reduce the stress concentration in the concrete stress process, and the breaking strength and the compressive strength are improved. Wherein, the dosage of the micro-beads is 0.1 to 10 percent. The dosage of the micro-beads is not suitable to exceed the range, and the optimal dosage is reached when the dosage is 2 percent.

The micro-bead is a superfine (submicron grade) global mineral admixture. The micro-beads have a particle morphology effect, a micro-aggregate effect and an activity effect. The addition of microbeads is related to the properties of the cement slurry as follows: (1) and in a certain addition amount range, along with the increase of the mixing amount of the microbeads, the fluidity of the cement paste tends to be increased after being reduced, the mixing amount of the microbeads is continuously increased, and the fluidity of the cement paste is not changed any more. The particle size of the micro-beads is small, the specific surface area is large, when the mixing amount is small, the morphological effect of the micro-beads cannot be exerted, and the high specific surface area adsorbs a certain amount of free water, so that the fluidity of the cement is not increased or decreased; after the mixing amount of the micro-beads reaches a certain value, the morphological effect of the micro-beads gradually plays a role, the ball effect of the micro-beads greatly increases the fluidity of the cement paste, the fluidity of the cement paste gradually increases, but the increase amplitude of the fluidity of the cement paste gradually decreases along with the gradual increase of the adding amount of the micro-beads. (2) The micro-beads have a centralized particle size distribution range, the average particle size is about 1.5 mu m, and the particle size of cement particles is about 5-50 mu m, so that the extremely narrow particle size distribution of the micro-beads can ensure that the micro-beads can better fill gaps among other rubber materials, play a micro-aggregate accumulation effect, enable a concrete structure to be more compact, and macroscopically show that the strength is higher. The addition amount of the micro-beads is too low, the micro-aggregate accumulation effect is not obvious, and gaps are not filled fully, while the addition amount of the micro-beads is too high, so that local agglomeration is caused, and the strength of hardened concrete is reduced. (3) The micro-beads contain much SiO ₂ 、Al ₂ O ₃ The active substances can perform secondary hydration reaction with free calcium hydroxide in the cement, and the formed needle-shaped calcium silicate and ettringite hydrate are inserted between gels to form a three-dimensional network structure to fill gaps of hardened concrete, so that the concrete has higher strength, the anti-erosion capability of the concrete can be improved, and the durability of the concrete is enhanced. When the adding amount of the micro-beads is within a certain range, the activity effect is gradually enhanced, the concrete strength is also gradually enhanced,however, when the amount of the added micro beads reaches a certain value, the relative content of the cement is reduced by continuously adding the micro beads, which in turn causes the strength of the concrete to be reduced. (4) The addition of the micro-beads can reduce water consumption, reduce the water-cement ratio in high-performance concrete, reduce the viscosity of concrete mixture, improve pumpability and facilitate super high-rise pumping. In addition, the microbeads are expensive, the mixing amount of the microbeads in the mixing proportion is not too high, the cost of the concrete is increased due to the too high mixing amount, the economic benefit is not good, and the consumption of the microbeads is reduced as much as possible on the premise of ensuring the viscosity reduction and the enhancement effect of the microbeads to be fully exerted. Based on the action mechanism of the microbeads, in the system disclosed by the invention, when the using amount of the microbeads is 2%, the particle morphology effect, the micro-aggregate effect, the activity effect and the economic effect of the microbeads reach optimal values.

The water reducing agent is a polycarboxylic acid water reducing agent, and is used in an amount of 0.01 to 2%, and is not typically, for example, 0.01%, 0.02%, 0.04%, 0.06%, 0.08%, 0.09%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1.0%, 1.2%, 1.4%, 1.6%, 1.8%, 2.0%. And more preferably 0.3%. Under the condition of low-dosage high-performance polycarboxylate superplasticizer, the water consumption can be reduced, the higher slurry plasticizing effect can be exerted, obvious delayed coagulation is not caused under the condition of effectively preventing slump loss, the mortar has better workability, and the strength and the durability of the hardened concrete are obviously improved. The molecular structure of the polycarboxylic acid high-efficiency water reducing agent is in a comb shape, and the main chain of the polycarboxylic acid high-efficiency water reducing agent is provided with a plurality of active groups with stronger polarity, such as-SO ₃ And the side chain is provided with a plurality of weak polar hydrophilic groups which have good affinity with water molecules and interact with the water molecules to form a stable solvated water film on the surface of the cement particles, so that the cement particles are prevented from being close together and have a lubricating effect among the particles, and therefore, after the high-performance polycarboxylate water reducer is doped, the concrete can be easily and uniformly mixed by using a small amount of water, and the workability of the mortar is improved. After the polycarboxylic acid high-efficiency water reducing agent is added, the fluidity is obviously improved, the fluidity of cement mortar is increased along with the increase of the mixing amount of the polycarboxylic acid high-efficiency water reducing agent in a certain range, and when the mixing amount reaches 0.2 percent, water is addedThe initial fluidity of the cement mortar reaches the maximum value, when the mixing amount of the polycarboxylic acid high-efficiency water reducing agent is increased, the fluidity of the cement mortar is reduced, and when the mixing amount of the polycarboxylic acid high-efficiency water reducing agent reaches 2%, the mortar can have serious bottom scraping and bleeding phenomena. The reason is that when the mixing amount of the polycarboxylic acid high-efficiency water reducing agent is too large, the main chain is adsorbed on cement particles, and the side chain possibly influences the steric hindrance effect due to winding, so that the dispersion effect of the cement particles is influenced, and macroscopically, the fluidity of cement mortar is reduced.

Wherein the lithium carbonate is used in an amount of 0.01-2%. Atypical, for example, 0.01%, 0.02%, 0.04%, 0.06%, 0.08%, 0.09%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1.0%, 1.2%, 1.4%, 1.6%, 1.8%, 2.0%. And more preferably 0.05%. Because the cement setting time is prolonged and the early strength is reduced after the high-efficiency water reducing agent is doped, the lithium carbonate is added to the cement setting time to play a role in: the addition of proper amount of lithium carbonate can promote the dissolution of minerals and the formation of hydration products in the early stage of cement hydration, shorten the hydration induction period of cement, and improve the heat release rate and the heat release amount of early hydration of cement, thereby shortening the setting time and improving the early compressive strength of cement mortar. However, the excessive lithium carbonate is added to reduce the compressive strength of the cement in the later period, because the dense hydration product layer generated in the early stage of cement hydration wraps the hydration minerals after the lithium carbonate is added, so that the later hydration process is delayed.

Wherein the dosage of the sodium gluconate is 0.01-2%. Atypical, for example, 0.01%, 0.02%, 0.04%, 0.06%, 0.08%, 0.09%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1.0%, 1.2%, 1.4%, 1.6%, 1.8%, 2.0%. And more preferably 0.05%. The dosage of the sodium gluconate is not suitable to exceed the range, and the optimal dosage is reached when the dosage is 0.05 percent. Due to the complexity of cement varieties, the adaptability problem of cement and a water reducing agent exists, and the phenomenon that the slump loss of concrete is too fast is caused. In particular, the cement fineness is increased after the cement is subjected to ISO standard, and the problem is more prominent. The sodium gluconate is added to the cement concrete, and the functions of (1) obviously improving the dispersibility and dispersion retentivity of the polycarboxylate water reducer, improving the water reducing rate, reducing the slump loss and improving the adaptability of the cement and the polycarboxylate water reducer are as follows: hydroxyl in sodium gluconate molecules can enable the surfaces of cement particles to form more stable solvated water films, so that contact points among the particles are reduced, more free water is left in the cement paste, coagulation among hydration products is hindered, bridging among the particles is weakened, and a retarding effect is achieved. (2) The addition of a proper amount of sodium gluconate can promote the hydration of tricalcium silicate, increase the generation amount of calcium hydroxide, facilitate the development of later strength, and reduce the early strength of cement mortar after a certain amount of sodium gluconate is added.

Wherein the diameter of the glass fiber is 5-10 μm, the length is 5-20mm, and the dosage is 0.01-2%. Atypical, for example, 0.01%, 0.02%, 0.04%, 0.06%, 0.08%, 0.09%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1.0%, 1.2%, 1.4%, 1.6%, 1.8%, 2.0%. And more preferably 0.3%. The glass fiber plays a role in enhancing the bending resistance and the breaking resistance of the bathroom deck panel in the formula, prevents the bathroom deck panel from cracking under certain bending or certain impact force, has an extremely low expansion coefficient at the using temperature of the bathroom deck panel, and can enhance and maintain the stability of the size of the bathroom deck panel. The amount of the glass fiber should not exceed this range. The cement has the advantages of high dosage, difficult dispersion, reduced mechanical property of cement, too low dosage, no reinforcement effect and reduced mechanical property. The optimal amount of the glass fiber is 0.3%. Among them, the glass fiber is too thin and long to be easily dispersed. Too coarse and too short will reduce the mechanical properties. The glass fiber has the function of reinforcing bars, can bear certain load and transfer stress, prevents the cement base material from cracking, and improves the problems of low tensile strength, low bending strength, brittleness and the like of the cement base material.

Wherein the low-temperature water-based emulsion is water-based polyurethane emulsion, water-based polyacrylic emulsion, water-based styrene butadiene rubber SBR emulsion, water-based natural rubber emulsion, water-based rosin emulsion or water-based terpene emulsion. Most preferred among them is an aqueous polyacrylic emulsion, which has a significantly better effect on enhancing the performance of a cement substrate than other low-temperature aqueous emulsions. The dosage of the low-temperature water-based emulsion is 0.1-6%. Atypical, for example, 0.1%, 0.2%, 0.3%, 0.5%, 0.6%, 0.8%, 1.0%, 1.2%, 1.4%, 1.6%, 1.8%, 2.0%, 2.2%, 2.4%, 2.6%, 2.8%, 3.0%, 3.2%, 3.4%, 3.6%, 3.8%, 4.0%, 4.2%, 4.4%, 4.6%, 4.8%, 5.0%, 5.2%, 5.4%, 5.6%, 5.8%, 6.0%. And more preferably 2.5%.

Referring to fig. 1, the present invention further provides a flow chart of a method for manufacturing the artificial bathroom deck panel.

S1: preparation of cement paste

Adding 20-60% of cement, 30-70% of quartz sand, 0.1-10% of micro-beads, 0.01-2% of water reducing agent, 0.01-2% of lithium carbonate, 0.01-2% of sodium gluconate, 0.01-2% of glass fiber and 0.1-6% of low-temperature water-based emulsion into water together according to the mass percentage, controlling the water-to-cement ratio to be 0.25-0.5 and the cement-to-sand ratio to be 0.25-0.7, and uniformly stirring to prepare the cement paste with the initial automatic fluidity of 200-250 mm.

S2: surface treatment of molds

The mould comprises a mould frame and a flat plate, and the mould frame is placed on the flat plate; before injection molding, coating inorganic nano emulsion on the inner wall of a mold frame and the surface of a flat plate; the inorganic nano emulsion is prepared by dispersing an inorganic nano micro powder material and a surfactant in water for emulsification.

Wherein the flat plate in the mould is one of a toughened glass plate, a wood plate, a cement plate or a metal plate with a smooth surface; the inorganic nano emulsion is silicon dioxide nano emulsion, aluminum oxide nano emulsion, titanium oxide nano emulsion or ferric oxide nano emulsion.

S3 injection moulding

Pouring the cement paste prepared in the step S1 into a mold frame, after vibration and flattening, standing and curing for 1-3h under natural conditions, carrying out extrusion and polishing on the surface of the cement paste in the mold frame by using a polishing machine while the thickness is uniform and within a specified size, demolding, and curing to obtain the cement substrate.

If the crack resistance and the impact resistance of the cement substrate are to be enhanced, a layer of glass fiber net can be added, and the aperture of the meshes of the glass fiber net is 0.5-5cm. At this time, the pouring can be performed twice: pouring 1/2 of the total module thickness, then placing a layer of glass fiber net, vibrating and paving, then continuously pouring 1/2 of the total module thickness, and then vibrating and paving.

The maintenance is carried out for 12-48h in constant temperature water of 40-80 ℃, and the maintenance method is any one of the following modes:

the method I comprises the following steps: spraying constant-temperature water at 40-80 ℃ on the surface of the cement substrate, and keeping the surface moist;

S4, surface treatment of the cement substrate

And (3) after the maintenance is finished, coating a layer of nano ceramic emulsion with the function of preventing water permeation on the surface of the cement substrate, and drying to obtain the artificial bathroom counter top. Preferably, the nano ceramic emulsion contains ceramic particles with the particle size of 5-20 nanometers, and the solid content is 20-60 percent; the emulsion also contains water, dispersant and binder such as polyacrylic acid. The dispersing agent is PVP, PEG or the like.

Preferably, after the nano ceramic emulsion is dried, a layer of decorative pattern paint or baking enamel paint or decorative concrete mortar is sprayed to ensure that the nano ceramic emulsion has aesthetic property. The adhesive force of the paint such as paint on the surface is 1-2 grade. (adhesion test Standard GB 1720-1979 (1989), with grade 1 being the highest Standard.)

According to the concept of the invention, the bathroom counter panel with the specification of 800mm, 500mm and 40mm is taken as an example to illustrate the characteristics and technical effects of the technical scheme of the invention.

Example 1

The preparation method of the bathroom deck panel of the embodiment comprises the following steps:

(1) According to the mass percentage, 34.5 percent of 42.5R cement, 60.55 percent of quartz sand with the thickness of 0.01-5mm, 1 percent of Beijing micro-beads, 1.5 percent of polycarboxylic acid water reducing agent, 0.1 percent of lithium carbonate, 0.05 percent of sodium gluconate, 0.3 percent of glass fiber (6 mm and glass fiber easy to disperse in Taishan mountain) and 2.0 percent of aqueous polyacrylic acid emulsion are added into water together, the water-cement ratio is controlled to be 0.25, the cement-sand ratio is in a control range at the moment, the stirring is uniform, and cement paste with the initial fluidity of 234mm is prepared.

(2) And (5) building a die. A frame (frame inner dimension 800mm 500mm 40mm) was placed on the plate surface. Before injection molding, the inner wall and the surface of the flat plate of the mold frame are coated with a layer of nano-silica emulsion with the concentration of 10%.

(3) And filling cement slurry into the mold frame, and after vibrating and paving the mold frame, filling the mold frame with the cement slurry. Then, standing the cement substrate with the mold frame for 2.5 hours under natural conditions, extruding and polishing the cement slurry on the top surface by using a high-speed rotary polisher to ensure that the surface thickness is uniform and flat and is within a specified size, demolding, and maintaining for 24 hours by using constant-temperature water at 60 ℃ after demolding to obtain the cement substrate.

(4) And coating a layer of nano ceramic emulsion with a waterproof and penetrating effect on the surface of the cement substrate, and drying to obtain the artificial bathroom countertop. The nano ceramic emulsion contains ceramic particles with the particle size of 5-20 nanometers, and the solid content is 40 percent; the emulsion also contains water, PVP dispersant 5%, polyacrylic acid 10% and other adhesive. And finally, performing surface painting or baking finish according to the required color or pattern.

Example 2 to example 10 were obtained in the following order according to the formulations in table 1 below, with reference to the procedure of example 1.

TABLE 1 concrete mix proportion

The slurries obtained from the cement formulations of examples 2-10 were tested for initial fluidity as shown in Table 2 (mortar fluidity measured by GB/T2419-2005 "Cement mortar fluidity test method"). Meanwhile, the bathroom deck panels were tested for compressive strength and bending strength under natural conditions for curing for 2.5 hours at 60 ℃ in constant temperature water for 3d and 7d according to the national standard GBT17671-1999, and the results are shown in Table 2.

TABLE 2 Performance index of Cement mortar or hardened concrete

From the test results of example 3 to example 1, it can be seen that: as the addition amount of the high polycarboxylic acid water reducing agent is increased, the water required to be added into the cement mortar is reduced, and the fluidity of the mortar is improved along with the reduction of the water-cement ratio. When the micro-beads are used in cement concrete, the pores among cement particles can be filled, so that free water can be discharged, the effect of reducing water consumption can be achieved, and the rolling effect of the micro-beads can increase the fluidity of mortar. Meanwhile, the addition of the water reducing agent and the microbeads can properly adjust the rubber-sand ratio, so that lower cost and higher performance are obtained. Thus, the variables water-reducing agent, microbeads, mortar ratio, and water-to-cement ratio are interdependent, and the 4 variables need to be adjusted to appropriate values in order to obtain a mortar with appropriate fluidity and workability, and to obtain a hardened concrete with high compressive and flexural strength.

From the test results of examples 4 to 6, it can be seen that: the addition of a proper amount of lithium carbonate can promote the dissolution of minerals and the formation of hydration products in the early stage of cement hydration, shorten the hydration induction period of cement, and improve the heat release rate and the heat release amount of the early stage of cement hydration, thereby shortening the setting time and improving the early compressive strength of cement mortar. The action rule of lithium carbonate is as follows: the addition of a proper amount of lithium carbonate has no great influence on the fluidity of the mortar and mainly influences the mechanical property of the mortar, the early compressive strength and the early flexural strength of the mortar are obviously enhanced along with the addition of the lithium carbonate, which means that the setting time is shortened, but certain negative effects are exerted on the later compressive strength and the later flexural strength of the mortar, and the reason is that after the lithium carbonate is doped, a compact hydration product layer generated in the early stage of cement hydration wraps hydrated minerals, so that the later stage hydration process is delayed.

From the test results of example 5 and examples 7 and 8, it can be seen that: the sodium gluconate can obviously improve the dispersibility and dispersion retentivity of the polycarboxylate superplasticizer, and improve the water reducing rate: hydroxyl in sodium gluconate molecules can enable the surfaces of cement particles to form more stable solvated water films, so that contact points among the particles are reduced, more free water is left in the cement paste, coagulation among hydration products is hindered, bridging among the particles is weakened, and a retarding effect is achieved. 2. The addition of a proper amount of sodium gluconate can promote the hydration of tricalcium silicate, increase the generation amount of calcium hydroxide and facilitate the development of later strength. The action rule of the sodium gluconate obtained by the embodiment is as follows: with the increase of sodium gluconate, the water-gel ratio can be gradually reduced, and the time required for reaching the same early strength is prolonged, and in addition, the early strength is reduced and the later strength is increased.

From the test results of examples 5 and 9 and 10, it can be seen that the low temperature aqueous emulsion can increase the toughness of the bathroom deck panel and improve the bending strength of the bathroom deck panel. The flexural strength increases with increasing low temperature aqueous emulsions.

The bathroom deck panel should be finally explained as follows: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. The artificial bathroom deck plate is characterized by comprising a cement substrate, wherein the cement substrate is integrally cast and molded by cement slurry; the cement paste consists of the following components: 20-60% of cement, 30-70% of quartz sand, 0.1-10% of micro-beads, 0.01-2% of a water reducing agent, 0.01-2% of lithium carbonate, 0.01-2% of sodium gluconate, 0.01-2% of glass fibers and 0.1-6% of low-temperature water-based emulsion; adding water into the materials of the components and mixing to obtain cement paste; the water-cement ratio of the cement paste is 0.25-0.5, and the cement-sand ratio is 0.25-0.7; the initial automatic fluidity of the cement paste is 200-250mm;

the granularity of the quartz sand is 0.01-5 mm; the particle size distribution range of the micro-beads is that d10 is less than or equal to 0.5 mu m, d50 is less than or equal to 1.5 mu m, and d95 is less than or equal to 5 mu m; the water reducing agent is a polycarboxylic acid water reducing agent; the low-temperature water-based emulsion is water-based polyurethane emulsion, water-based polyacrylic acid emulsion, water-based Styrene Butadiene Rubber (SBR) emulsion, water-based natural rubber emulsion, water-based rosin emulsion or water-based terpene emulsion;

the cement is a mixture of one or more of the numbers 32.5, 32.5R, 42.5R, 52.5R, 62.5 and 62.5R.

2. The artificial bathroom deck panel according to claim 1, wherein the bathroom deck panel comprises the cement substrate, a nano ceramic emulsion coated on the surface of the cement substrate for preventing water penetration; or the bathroom deck panel comprises the cement substrate, nano ceramic emulsion which is coated on the surface of the cement substrate and plays a role in preventing water penetration, and a decorative pattern layer on the outermost side.

3. A method for preparing the artificial bathroom deck as claimed in claim 1 or 2, comprising:

s1: preparation of cement paste

Adding 20-60% of cement, 30-70% of quartz sand, 0.1-10% of micro-beads, 0.01-2% of water reducing agent, 0.01-2% of lithium carbonate, 0.01-2% of sodium gluconate, 0.01-2% of glass fiber and 0.1-6% of low-temperature water-based emulsion into water according to the mass percentage, controlling the water-to-cement ratio to be 0.25-0.5 and the cement-to-sand ratio to be 0.25-0.7, and uniformly stirring to prepare cement paste with the initial automatic fluidity of 200-250mm; the cement is a mixture of one or more of the numbers 32.5, 32.5R, 42.5R, 52.5R, 62.5 and 62.5R;

s2: surface treatment of molds

s3 injection moulding

s4, surface treatment of the cement substrate

And coating a layer of nano ceramic emulsion with a waterproof and penetrating effect on the surface of the cement substrate, and drying to obtain the artificial bathroom table panel.

4. The manufacturing method according to claim 3, wherein in step S2, the flat plate in the mold is one of a tempered glass plate with a smooth surface, a wood plate, a cement plate or a metal plate; the inorganic nano emulsion is silicon dioxide nano emulsion, aluminum oxide nano emulsion, titanium oxide nano emulsion or ferric oxide nano emulsion.

5. The preparation method according to claim 3, wherein in step S3, the casting is performed in two steps, wherein 1/2 of the total module thickness is cast, then a layer of glass fiber mesh is placed, the vibration is performed for leveling, then 1/2 of the total module thickness is cast continuously, and then the vibration is performed for leveling.

6. The preparation method according to claim 3, wherein in the step S3, the curing is performed in constant-temperature water at 40-80 ℃ for 12-48h, and the curing method is any one of the following manners:

7. The preparation method according to claim 3, wherein in step S1, the low-temperature aqueous emulsion is a low-temperature aqueous emulsion selected from an aqueous polyurethane emulsion, an aqueous polyacrylic acid emulsion, an aqueous Styrene Butadiene Rubber (SBR) emulsion, an aqueous natural rubber emulsion, an aqueous rosin emulsion and an aqueous terpene emulsion; in step S4, the nano ceramic emulsion contains ceramic particles with the particle size of 5-20 nanometers, and the solid content is 20-60%; the nano ceramic emulsion also contains water, a dispersing agent and a binder.