Introduction
Sintered stone slabs are becoming increasingly popular in the construction and decoration markets due to their durability, aesthetic appeal, and versatility. However, as these slabs get bigger and thinner, they present significant challenges in transportation and delivery. Their rigidity makes them prone to breaking, necessitating innovative solutions to enhance their structural integrity. One such solution is the application of composite glass fiber mesh on the back of the slabs using two-component polyurethane adhesives. This guide delves into the process and benefits of this method, providing a comprehensive overview for sintered stone slab factories.
Advantages of Two-Component Polyurethane Adhesives
Two-component polyurethane adhesives are composed of polyols and poly-isocyanates or urethane prepolymers that are mixed just before application. This mixture results in a chemical reaction that creates a strong, durable bond. Here are some key advantages of using two-component polyurethane adhesives:
- Good Weather Resistance: These adhesives can withstand various environmental conditions, making them suitable for both indoor and outdoor applications.
- High Peel Strength: With a peel strength greater than 50 N/cm, these adhesives provide robust bonding, ensuring the longevity of the composite slabs.
- Low Cost: Despite their high performance, two-component polyurethane adhesives are cost-effective, making them an economical choice for large-scale production.
- Solvent-Free and Environmentally Friendly: These adhesives do not contain solvents, reducing their environmental impact and making them safer to use.
- Low Investment in Production Equipment: The equipment required for applying these adhesives is relatively inexpensive, further reducing overall production costs.
Production Process
The production process for compositing glass fiber mesh onto sintered stone slabs involves several key steps, each designed to ensure high quality and efficiency. The following outlines the recommended process using HSB adhesive’s automatic composite sintered stone slab back mesh process solution:
- Preparation of Fiberglass Mesh:
- The fiberglass cloth is first coated with hot melt adhesive PUR. The recommended amount of glue is 90 g/㎡. This step seals the glass fiber mesh, preventing the stacked slabs from sticking together due to the polyurethane adhesive.
- Application of Polyurethane Adhesive:
- An automatic coating machine is used to apply the HSB composite back mesh special two-component polyurethane adhesive to the back of the sintered stone slab. The recommended amount of glue is 200 g/㎡. This ensures a uniform and strong adhesive layer.
- Composite Process:
- The coated fiberglass mesh and the sintered stone slab are then pressed together using an automatic roller press. This step ensures that the mesh is firmly bonded to the slab.
- Curing:
- The composite sintered stone slabs are stacked and placed under gravity pressure for 2 hours for initial curing. This step is crucial for achieving the desired bond strength before the slabs are inspected, packaged, and shipped.
Benefits of the Process
Implementing this process offers several benefits:
- Enhanced Durability: The fiberglass mesh significantly improves the bending resistance of the sintered stone slabs, reducing the risk of breakage during transportation and installation.
- High Efficiency: The use of automatic coating machines and roller presses streamlines the production process, increasing output and reducing labor costs.
- Consistent Quality: Automated processes ensure uniform application of adhesives and consistent quality across all slabs.
- Cost-Effectiveness: The low cost of two-component polyurethane adhesives and minimal investment in production equipment make this process economically viable for large-scale operations.
Conclusion
The integration of two-component polyurethane adhesives and fiberglass mesh in the production of sintered stone slabs addresses the challenges posed by their increasing size and thinness. By following the outlined process, factories can produce high-quality, durable slabs efficiently and economically. This approach not only enhances the structural integrity of the slabs but also aligns with environmental sustainability goals, making it a forward-thinking solution for the modern construction and decoration markets.
Related reference
6 Adhesive Types for Stone – Explained for Fabricators
An introduction to the benefits and applications of sintered stone