Graphene modified phenolic foam soundproof board and preparation method thereof

Abstract

The application relates to the field of building materials, in particular to a graphene modified phenolic foam sound insulation board and a preparation method thereof. The graphene modified phenolic foam sound insulation board comprises an outer layer and a phenolic foam layer arranged between two outer layers, and the raw materials of the phenolic foam layer comprise phenolic resin, an emulsifier, graphene, a foaming agent and a curing agent; the mass ratio of the phenolic resin, the emulsifier, the graphene, the foaming agent and the curing agent is 1:(0.08-0.2):(0.02-0.06):(0.03-0.09):(0.1-0.3). The phenolic foam layer prepared from phenolic foam and graphene sheets can form resonance absorption with the sound wave vibration of a floor, so that the effect of noise reduction and sound insulation is achieved. The phenolic foam board with added graphene has high structural strength and good fireproof performance, and has great practical application value in the field of building sound insulation.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of building materials, in particular to a graphene modified phenolic foam sound insulation board and a preparation method thereof. BACKGROUND

[0002] With the improvement of people's living quality, people's requirements for living environment are also getting higher and higher, among which living noise is an important consideration for most people when choosing living environment. In order to reduce the influence of living noise, the construction method of adding sound insulation materials between floors has been widely promoted. The working principle of sound insulation materials is to prevent the propagation of sound by absorption, reflection, scattering and other ways. Sound insulation materials usually have high density and softness, which can effectively absorb the energy of sound waves, thereby reducing the propagation of sound. In addition, sound insulation materials can also change the propagation direction and path of sound waves by reflection and scattering, thereby achieving sound insulation effect.

[0003] At present, some sound insulation boards on the market are made by installing a rubber layer between two plates, however, such sound insulation boards have limited sound insulation effect, and with the extension of use time, the rubber will slowly age in the air, causing it to gradually harden and lose elasticity, thereby causing the sound insulation effect to gradually decrease over time. Therefore, it is necessary to find other materials to prepare sound insulation boards with better sound insulation effect. SUMMARY

[0004] In order to solve the problem of insufficient sound insulation effect of the existing sound insulation board, the present application provides a graphene modified phenolic foam sound insulation board and a preparation method thereof.

[0005] The present application provides a graphene modified phenolic foam sound insulation board, which comprises an outer layer and a phenolic foam layer arranged between two outer layers, and the raw materials of the phenolic foam layer include phenolic resin, emulsifier, graphene, foaming agent and curing agent, and the mass ratio of the phenolic resin, emulsifier, graphene, foaming agent and curing agent is 1:(0.08-0.2):(0.02-0.06):(0.03-0.09):(0.1-0.3).

[0006] Preferably, the mass ratio of the phenolic resin, emulsifier, graphene, foaming agent and curing agent is 1:0.1:(0.02-0.05):0.05:0.15. If too much graphene is added, the mixture will be too thick and cannot be produced normally; if the amount of graphene added is too small, the effect cannot be achieved, affecting the performance of the product.

[0007] Further, the phenolic resin is synthesized from phenol and formaldehyde under alkaline conditions.

[0008] Further, the preparation method of the phenolic resin comprises the following steps: adding phenol, liquid formaldehyde, solid formaldehyde and a catalyst into a reaction container, stirring and mixing uniformly, and heating to 80-85℃, and reacting for 4-6h to obtain the phenolic resin.

[0009] Further, the mass ratio of the phenol, liquid formaldehyde and solid formaldehyde is 3:(0.5-2):(1-2.5), preferably 3:1:1.24.

[0010] Further, the catalyst is sodium hydroxide or potassium hydroxide.

[0011] Further, the viscosity of the phenol resin is 1000-1500mPa·s.

[0012] Further, the outer layer is at least one of cement roll material, aluminum foil, non-woven fabric, glass felt and cotton.

[0013] Further, the emulsifier is silicone oil or castor oil.

[0014] Further, the foaming agent is n-pentane or isopentane.

[0015] The curing agent is p-methylbenzenesulfonic acid or phosphoric acid.

[0016] The application further provides a preparation method of the graphene-modified phenolic foam soundproof board.

[0017] (1) stirring and mixing the phenolic resin, the emulsifier, the graphene and the foaming agent to obtain a mixed emulsion;

[0018] (2) stirring and mixing the mixed emulsion and the curing agent, and then pouring the mixture between two layers of roll material, and foaming and curing at 65-75℃ to obtain the graphene-modified phenolic foam soundproof board.

[0019] Compared with the prior art, the graphene-modified phenolic foam soundproof board provided by the application can form resonance absorption with the sound wave vibration of the floor through the phenolic foam layer prepared from the phenolic foam and the graphene sheet layer, so that the noise reduction and sound insulation effect is achieved. The phenolic foam board added with graphene has high structural strength and good fireproof performance, and has great practical application value in the field of building sound insulation. DETAILED DESCRIPTION

[0020] In order to make the purpose, technical scheme and advantages of the embodiments of the application clearer, the technical scheme of the embodiments of the application will be described clearly and completely below. Obviously, the described embodiments are some of the embodiments of the application, but not all the embodiments of the application. Based on the embodiments of the application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the application.

[0021] The application provides a graphene modified phenolic foam sound insulation board, which comprises outer layers and a phenolic foam layer arranged between the two outer layers, and the raw materials of the phenolic foam layer comprise phenolic resin, emulsifier, graphene, foaming agent and curing agent, and the mass ratio of the phenolic resin, the emulsifier, the graphene, the foaming agent and the curing agent is 1:(0.08-0.2):(0.02-0.06):(0.03-0.09):(0.1-0.3).

[0022] The phenolic resin is prepared by the following method: phenol, liquid formaldehyde, solid formaldehyde and a catalyst are added into a reaction container, stirred and uniformly mixed, and heated to 80-85 DEG C, and then reacted for 4-6 h to obtain the phenolic resin.

[0023] The outer layer is at least one of cement roll material, aluminum foil, non-woven fabric, glass felt and cotton.

[0024] The emulsifier is silicone oil or castor oil.

[0025] The foaming agent is n-pentane or isopentane.

[0026] The curing agent is p-methylbenzenesulfonic acid or phosphoric acid.

[0027] The application further provides a preparation method of the graphene modified phenolic foam sound insulation board.

[0028] (1) the phenolic resin, the emulsifier, the graphene and the foaming agent are stirred and uniformly mixed to obtain a mixed emulsion;

[0029] (2) the mixed emulsion is stirred and uniformly mixed with the curing agent, then poured between the two roll materials, and foamed and cured at 65-75 DEG C to obtain the graphene modified phenolic foam sound insulation board.

[0030] Example 1

[0031] The graphene modified phenolic foam sound insulation board comprises outer layers and a phenolic foam layer arranged between the two outer layers, and the outer layer is cement roll material. The preparation method of the graphene modified phenolic foam sound insulation board is as follows:

[0032] (1) phenol, liquid formaldehyde and solid formaldehyde are added into a reaction container, wherein the mass ratio of the phenol, the liquid formaldehyde and the solid formaldehyde is 3:1:1.24, 5% of sodium hydroxide based on the mass of the phenol is further added, stirred and uniformly mixed, heated to 82 DEG C at a rate of 5 DEG C / min, and then reacted for 5 h to obtain the phenolic resin;

[0033] (2) the phenolic resin, the silicone oil, the graphene and the n-pentane prepared in step (1) are stirred and uniformly mixed to obtain a mixed emulsion, wherein the mass ratio of the phenolic resin, the silicone oil, the graphene and the n-pentane is 1:0.1:0.03:0.05;

[0034] (3) in the preparation of foaming heating box laid a layer of cement roll, the mixed emulsion prepared in step (2) and phosphoric acid is stirred and mixed, poured on the cement roll, then laid a layer of cement roll, foaming solidification at 70℃, then obtained; wherein the mass of phosphoric acid is 15% of the mass of phenolic resin.

[0035] The modified phenolic foam sound insulation board has a closed cell rate of 93% by true density tester.

[0036] The weighted normalized impact sound pressure level of the reinforced concrete floor is L n,w = 78 dB. The 10mm thick sound insulation board is laid on the floor, and a 40mm thick concrete layer is laid on the surface. The impact sound insulation test (test basis: GB / T 50121-2005 "Building sound insulation evaluation standard"; GB / T 19889.8-2006 / ISO 140-8:1997 "Acoustics - Measurement of sound insulation in buildings and of building elements under in-situ conditions - Part 8: Laboratory measurement of the in- situ impact sound improvement of a floor covered with a heavy mass layer") shows that the overall structure weighted normalized impact sound pressure level L n,w = 60 dB, and the weighted impact sound pressure level improvement ΔL w = 18 dB. According to the floor impact sound insulation standard in GB50118-2010 "Design code for sound insulation of civil buildings", the impact sound insulation performance of the floating floor meets the corresponding grade standards of residential buildings, school buildings, hospital buildings and hotel buildings.

[0037] Example 2

[0038] A graphene modified phenolic foam sound insulation board comprises an outer layer and a phenolic foam layer arranged between two outer layers, and the outer layer is a non-woven fabric. The preparation method of the graphene modified phenolic foam sound insulation board is as follows:

[0039] (1) phenol, liquid formaldehyde and solid formaldehyde are added to a reaction container, wherein the mass ratio of phenol, liquid formaldehyde and solid formaldehyde is 3:0.5:2.5, 5% of the mass of sodium hydroxide is added, stirred and mixed, heated to 80℃ at a rate of 5℃ / min, and reacted for 6h to obtain the phenolic resin;

[0040] (2) the phenolic resin, silicon oil, graphene and isopentane prepared in step (1) are stirred and mixed to obtain a mixed emulsion, wherein the mass ratio of phenolic resin, silicon oil, graphene and isopentane is 1:0.2:0.06:0.09;

[0041] (3) in the preparation of foaming heating box laid a layer of non-woven fabric, the mixed emulsion prepared in step (2) and phosphoric acid is stirred and mixed, poured on the non-woven fabric, then laid a layer of non-woven fabric, foaming solidification at 65℃, then obtained; wherein the mass of phosphoric acid is 30% of the mass of phenolic resin.

[0042] The modified phenolic foam sound insulation board has a closed cell rate of 92% detected by a true density tester.

[0043] The weighted normalized impact sound pressure level of the reinforced concrete floor is L n,w = 78 dB. The 10mm-thick sound insulation board is laid on the floor, and a 40mm-thick concrete layer is laid on the surface. The weighted normalized impact sound pressure level of the overall structure is L n,w = 60 dB, and the weighted impact sound pressure level improvement AL w = 18 dB. According to the floor impact sound insulation standards in GB50118-2010 "Design Code for Sound Insulation of Civil Buildings", the impact sound insulation performance of the floating floor meets the corresponding grade standards of residential buildings, school buildings, hospital buildings and hotel buildings.

[0044] Example 3

[0045] A graphene-modified phenolic foam sound insulation board comprises an outer layer and a phenolic foam layer arranged between two outer layers, and the outer layer is a glass fiber felt. The preparation method of the graphene-modified phenolic foam sound insulation board is as follows:

[0046] (1) phenol, liquid formaldehyde and solid formaldehyde are added to a reaction container, wherein the mass ratio of phenol, liquid formaldehyde and solid formaldehyde is 3:2:1, 5% of the mass of phenol is added sodium hydroxide, stirred and mixed, heated to 85℃ at a rate of 5℃ / min, and reacted for 4h to obtain the phenolic resin;

[0047] (2) the phenolic resin, castor oil, graphene and n-pentane obtained in step (1) are stirred and mixed to obtain a mixed emulsion, wherein the mass ratio of phenolic resin, castor oil, graphene and n-pentane is 1:0.08:0.02:0.03;

[0048] (3) a layer of glass fiber felt is laid in a heating box ready for foaming, the mixed emulsion obtained in step (2) is stirred and mixed with p-toluenesulfonic acid, poured on the glass fiber felt, and then another layer of glass fiber felt is laid, and after foaming and curing at 75℃, the graphene-modified phenolic foam sound insulation board is obtained; wherein the mass of p-toluenesulfonic acid is 10% of the mass of phenolic resin.

[0049] The modified phenolic foam sound insulation board has a closed cell rate of 90% detected by a true density tester.

[0050] The weighted normalized impact sound pressure level of the reinforced concrete floor is L n,w = 78 dB. The 10mm-thick sound insulation board is laid on the floor, and a 40mm-thick concrete layer is laid on the surface. The weighted normalized impact sound pressure level of the overall structure is L n,w = 60 dB, and the weighted impact sound pressure level improvement AL w= 18dB. According to the floor impact sound insulation standard in GB50118-2010 "Code for Design of Sound Insulation of Civil Buildings", the impact sound insulation performance of the floating floor meets the corresponding grade standard of residential buildings, school buildings, hospital buildings and hotel buildings.

[0051] Comparative Example 1

[0052] Different from Example 1, no graphene is added, and the remaining raw materials and preparation process are the same as those in Example 1.

[0053] The closed cell rate of the phenolic foam sound insulation board is 75% by the true density tester.

[0054] The weighted normalized impact sound pressure level of the 10mm-thick sound insulation board is L n,w = 78dB. After the sound insulation board is laid on the reinforced concrete floor, a 40mm-thick concrete layer is laid on the surface, and the impact sound insulation detection (the detection is based on the above) is carried out, the weighted normalized impact sound pressure level of the whole structure is L n,w = 66dB, and the improvement of the weighted impact sound pressure level is AL w = 12dB. It can be seen that the sound insulation effect of the phenolic foam sound insulation board without graphene is reduced.

[0055] As shown above, the graphene-modified phenolic foam sound insulation board has high closed cell rate and good sound insulation effect, and can make the building have good sound insulation effect when applied to building materials, and the preparation process is simple and can be widely used.

[0056] Finally, it should be noted that: the above examples are only used to illustrate the technical solutions of the present application, but not to limit them; although the present application has been described in detail with reference to the above examples, those skilled in the art should understand that: it can still modify the technical solutions recorded in the above examples, or make equivalent replacement for part or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present application.

Claims

1. A graphene-modified phenolic foam sound insulation board, characterized in that: The material includes an outer layer and a phenolic foam layer disposed between the two outer layers. The raw materials of the phenolic foam layer include phenolic resin, emulsifier, graphene, foaming agent, and curing agent. The mass ratio of the phenolic resin, emulsifier, graphene, foaming agent, and curing agent is 1:(0.08-0.2):(0.02-0.06):(0.03-0.09):(0.1-0.3). The preparation method of the phenolic resin is as follows: phenol, liquid formaldehyde, solid formaldehyde and catalyst are added to a reaction vessel, stirred and mixed, and heated to 80-85℃. The reaction is carried out for 4-6 hours to obtain the phenolic resin. The mass ratio of phenol, liquid formaldehyde, and solid formaldehyde is 3:(0.5-2):(1-2.5); the catalyst is sodium hydroxide or potassium hydroxide; and the viscosity of the phenolic resin is 1000-1500 mPa·s. The emulsifier is silicone oil or castor oil; the foaming agent is n-pentane or isopentane; and the curing agent is p-toluenesulfonic acid or phosphoric acid.

2. The graphene-modified phenolic foam sound insulation board according to claim 1, characterized in that: The mass ratio of the phenolic resin, emulsifier, graphene, foaming agent and curing agent is 1:0.1:(0.02-0.05):0.05:0.

15.

3. The graphene-modified phenolic foam sound insulation board according to claim 1, characterized in that: The outer layer is at least one of cement roll, aluminum foil, non-woven fabric, fiberglass felt, and cotton.

4. A method for preparing a graphene-modified phenolic foam sound insulation board according to any one of claims 1-3, characterized in that: Includes the following steps: (1) Stir and mix the phenolic resin, emulsifier, graphene and foaming agent to obtain a mixed emulsion; (2) After mixing the emulsion and the curing agent, pour it between the two layers of roll material and foam and cure at 65-75℃ to obtain the final product.