Production method of professional fireproof and soundproof door suitable for studio

Abstract

The invention provides a production method of a professional fireproof and soundproof door suitable for a studio, and belongs to the technical field of fireproof and soundproof doors, the production method of the professional fireproof and soundproof door suitable for the studio comprises the steps that firstly, a multi-layer structure mathematical model is constructed based on the sound transmission loss theory, and parameters are optimized; then main components of the door body are manufactured through high-precision machining, and the main components comprise a high-strength carbon steel plate outer layer, a flame-retardant high-density sound insulation felt and a middle layer sound insulation material; all layers of materials are assembled into a door body by adopting a laminating process; according to the parameter that Rw + C is larger than 40 dB according to the fact that the steel door plate is 2 mm + the sound insulation felt is 1 mm + the fire stone plate / graphene is 45 mm + the sound insulation felt is 1 mm + the steel door plate is 2 mm, the door frame is designed to be provided with three rabbets, and special sealing rubber strips are installed; assembling the hardware to complete door body assembly; and finally, a reverberation room method acoustic performance test, a fireproof performance test and a switch durability test are carried out to ensure that the product meets the studio standard requirements and the 1.5-hour fireproof grade, and the optimal balance of the sound insulation performance and the fireproof performance is realized.

Description

Technical Field

[0001] The present invention belongs to the technical field of fireproof and sound-insulating doors, and more specifically, relates to a production method of a professional fireproof and sound-insulating door applicable to a studio. Background Art

[0002] As a professional acoustic environment, a studio has strict requirements for the sound-insulating performance of the door body. At the same time, based on fire safety regulations, it also needs to meet specific fireproof performance standards. Traditional sound-insulating doors in studios usually adopt single materials or simple stacked structures, such as wooden sandwich panels, steel fire doors with sound-insulating materials added, etc. to achieve the sound-insulating function. The structural design of such door bodies mainly relies on empirical rules and lacks systematic acoustic theory guidance, making it impossible to accurately calculate and predict the sound-insulating performance of the door body.

[0003] However, traditional sound-insulating doors in studios have exposed many defects in practical applications: on the one hand, single materials are difficult to meet the dual requirements of sound insulation and fire protection at the same time; on the other hand, simple stacked structures often have the phenomenon of sound bridges, resulting in a significant attenuation of the sound-insulating effect. In addition, the sealing structure design of the door frame and the door leaf is insufficient, causing sound wave leakage and seriously weakening the overall sound-insulating effect, especially in the low-frequency region.

[0004] The core problem that the current technology cannot solve lies in the lack of a systematic design method based on a theoretical model, making it impossible to achieve the optimal balance between sound-insulating performance and fireproof performance. Traditional empirical designs cannot accurately predict the acoustic behavior of complex multi-layer structures, resulting in a lack of scientific basis for material selection and structural design during the production process, and the final product is difficult to meet the Rw + C value index and fireproof grade requirements of the GB / T19889.3 standard for studios. That is to say, there is a technical problem in the prior art that it is difficult for professional fireproof and sound-insulating doors in studios to simultaneously take into account sound-insulating performance, fireproof performance, and production feasibility. Summary of the Invention

[0005] In view of this, the present invention provides a production method of a professional fireproof and sound-insulating door applicable to a studio, which can solve the technical problem in the prior art that it is difficult for professional fireproof and sound-insulating doors in studios to simultaneously take into account sound-insulating performance, fireproof performance, and production feasibility.

[0006] The present invention is implemented as follows: The present invention provides a production method for a professional fireproof and sound-insulating door applicable to a studio, which includes the following operating steps: conducting acoustic isolation parameter design, constructing a mathematical model of a multi-layer structure based on the sound transmission loss theory, representing each layer structure of the door body as a weighted directed graph, and applying the minimum cut maximum flow algorithm to determine the optimal solution of the material combination; cutting high-strength carbon steel plates as the outer layer of the door; preparing flame-retardant high-density sound-insulating felt; processing the middle-layer sound-insulating material; assembling the door body using a lamination process; designing the door frame with three rabbets; installing special sealing rubber strips on the rabbet surface; assembling the hardware; conducting finished product testing, measuring the acoustic performance of the door body using the reverberation room method, detecting that the fireproof performance meets the fire resistance rating, and conducting a switch durability test to complete the production process; among them, the acoustic transmission matrix equations are used to replace the finite element model for the structural design and optimization of the sound-insulating door, including the material impedance equation, the interface transmission equation, the overall transmission equation, and the acoustic evaluation equation.

[0007] Among them, the acoustic isolation parameter design constructs a mathematical model of a multi-layer structure based on the sound transmission loss theory, represents each layer structure of the door body as a weighted directed graph, applies the minimum cut maximum flow algorithm to determine the optimal solution of the material combination, and optimizes the thickness parameters of each layer of materials to make the overall sound insulation performance meet the studio standard requirements; each layer structure of the door body refers to a multi-layer composite structure composed of high-strength carbon steel plates, flame-retardant high-density sound-insulating felt, and middle-layer sound-insulating materials, where the high-strength carbon steel plates are located in the outermost layer, the flame-retardant high-density sound-insulating felt is located in the second and fourth layers, and the middle-layer sound-insulating materials are located in the third layer.

[0008] Among them, the sound transmission loss theory specifically refers to the quantitative description of the energy attenuation when sound waves propagate from one medium to another, and calculates the sound energy transfer characteristics in the multi-layer structure through the mass law, resonance effect, and coincidence effect; the weighted directed graph specifically refers to a mathematical model used to represent the sound transmission relationship between material layers, where the nodes represent different material layers and the edge weights represent the sound energy transfer efficiency; the minimum cut maximum flow algorithm specifically refers to a graph theory optimization algorithm used to solve network flow problems and is used to find the optimal material combination scheme in the design of the sound-insulating door.

[0009] Among them, when cutting high-strength carbon steel plates as the outer layer of the door, numerical control cutting is used to ensure that the dimensional accuracy is within the range of ±0.5 mm, and then surface treatment is carried out, including rust removal, phosphating treatment, and primer spraying.

[0010] Among them, when preparing the flame-retardant high-density sound-insulating felt, polyester fiber and a flame retardant are mixed in a mass ratio of 4:1 and then hot-pressed into shape, and the density of the finished product is controlled at 150 to 200 kg per cubic meter, and the thickness is precisely controlled.

[0011] Among them, for the sound insulation material of the processing intermediate layer, the fire slate or graphene composite board is cut to the designed size according to the calculation parameters, and the edges are chamfered to ensure tight combination with the door frame; the fire slate specifically refers to a high-density fireproof board composed of calcium silicate and fiber materials, with excellent sound insulation characteristics and fireproof performance; the graphene composite board specifically refers to a new composite material formed by mixing graphene materials and polymer matrices, with the characteristics of light weight, high sound insulation performance and high fireproof grade.

[0012] Among them, for assembling the door body by the lamination process, high-strength carbon steel plates, flame-retardant high-density sound insulation felts, intermediate layer sound insulation materials, flame-retardant high-density sound insulation felts, and high-strength carbon steel plates are stacked in sequence, and epoxy structural adhesive is used for bonding, and it is pressed for 24 to 48 hours in an environment with a constant temperature of 25 to 30 degrees Celsius.

[0013] Among them, the door frame adopts a three-way rabbet design and is precisely processed by numerical control equipment. The depth of the rabbet is designed to be 8 to 12 millimeters, and the rabbet surface is completely perpendicular to ensure the sealing effect; the rabbet specifically refers to the concave-convex structure designed on the contact surface between the door leaf and the door frame, forming a labyrinth acoustic barrier to block the direct propagation path of sound waves; a special sealing strip is installed on the rabbet surface, and high-temperature-resistant silicone rubber material is selected, and the compression ratio is designed within the range of 15% to 20% to ensure airtight closure when the door body is closed.

[0014] Among them, for assembling the hardware, it includes heavy-duty self-closing hinges, multi-point locking devices and pressure regulators, and the gap between the door leaf and the door frame is adjusted to 2 to 3 millimeters.

[0015] Among them, the material impedance equation is used to calculate the acoustic characteristic parameters of each layer of material. The inputs include material density, Young's modulus, Poisson's ratio, material thickness and internal loss factor, and the outputs are the material characteristic impedance value and wave number; the interface transmission equation is used to calculate the propagation characteristics of sound waves at the interface of two materials. The inputs include the incident angle, incident energy, front and rear material characteristic impedances, interface bonding stiffness and interface thickness, and the outputs are the reflection coefficient and transmission coefficient; the overall transmission equation is used to integrate the acoustic transmission behavior of multi-layer structures. The inputs include the transmission matrices of each layer of material, the interface transmission matrix between layers, the total thickness of the structure and boundary conditions, and the output is the total transmission matrix of the system; the acoustic evaluation equation is used to quantitatively calculate the sound insulation performance index. The inputs include the total transmission matrix of the system, the standard frequency range, the reference sound pressure level and the environmental correction factor, and the outputs are the sound transmission loss value and the weighted sound insulation Rw + C value; the standard frequency range refers to the frequency interval for evaluating the sound insulation performance, which is 16 one-third octave bands from 100 Hz to 3150 Hz specified in the GB / T 19889.3 standard.

[0016] Compared with the prior art, the present invention provides a production method of a professional fireproof and sound-insulating door applicable to a studio. The present invention proposes a design and production method of a professional fireproof and sound-insulating door for a studio based on the acoustic transmission matrix theory. By constructing a mathematical model of a multi-layer structure, representing each layer structure of the door body as a weighted directed graph, and applying the minimum cut maximum flow algorithm to determine the optimal solution of the material combination, the comprehensive optimization of sound insulation performance and fireproof performance is realized.

[0017] This method solves multiple defects in the traditional technology: First, the acoustic isolation parameter design link ensures the theoretical feasibility of the door body structure and avoids the blindness of empirical design; Second, the multi-layer composite structure design (high-strength carbon steel plate, flame-retardant high-density sound-insulating felt, fire slate or graphene composite plate) effectively eliminates the sound bridge phenomenon; Third, the three-way rabbet design and the application of special sealing strips significantly improve the sealing performance of the door frame and the door leaf, effectively blocking the sound wave leakage path.

[0018] The present invention successfully solves the core technical problem of simultaneously considering sound insulation performance, fireproof performance and production feasibility of a professional fireproof and sound-insulating door for a studio, and provides a systematic technical solution for the acoustic environment control of a studio. Brief Description of the Drawings

[0019] Figure 1 It is a flowchart of the method of the present invention. Detailed Embodiments

[0020] To make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention.

[0021] As Figure 1 shown, it is a flowchart of a production method of a professional fireproof and sound-insulating door applicable to a studio provided by the present invention. This method includes the following steps:

[0022] S01. Conduct acoustic isolation parameter design, construct a mathematical model of a multi-layer structure based on the sound transmission loss theory, represent each layer structure of the door body as a weighted directed graph, apply the minimum cut maximum flow algorithm to determine the optimal solution of the material combination, and optimize the thickness parameters of each layer of materials to make the overall sound insulation performance meet the studio standard requirements;

[0023] S02. Cut a high-strength carbon steel plate as the outer layer of the door, ensure the dimensional accuracy within ±0.5 mm by numerical control cutting, and then perform surface treatment, including rust removal, phosphating treatment and primer spraying;

[0024] S03. Prepare a flame-retardant high-density sound-insulating felt, mix polyester fiber and a flame retardant in a mass ratio of 4:1 and then hot-press them into shape, control the finished product density at 150 to 200 kg per cubic meter, and accurately control the thickness;

[0025] S04. Process the intermediate layer sound insulation material, cut the firestone slab or graphene composite board to the designed size according to the calculated parameters, and chamfer the edges to ensure tight combination with the door frame;

[0026] S05. Assemble the door body using the lamination process, stack in sequence the high-strength carbon steel plate, flame-retardant high-density sound insulation felt, intermediate layer sound insulation material, flame-retardant high-density sound insulation felt, and high-strength carbon steel plate, bond them using epoxy structural adhesive, and press for 24 to 48 hours in an environment with a constant temperature of 25 to 30 degrees Celsius;

[0027] S06. The door frame adopts a three-way rabbet design, precisely processed using numerical control equipment, the rabbet depth is designed to be 8 to 12 mm, and the rabbet surface is completely perpendicular to ensure the sealing effect;

[0028] S07. Install a special sealing strip on the rabbet surface, select high-temperature resistant silicone rubber material, and the compression ratio is designed within the range of 15% to 20% to ensure airtight closure when the door body is closed;

[0029] S08. Assemble the hardware, including heavy-duty self-closing hinges, multi-point locking devices, and pressure regulators, and adjust the gap between the door leaf and the door frame to 2 to 3 mm;

[0030] S09. Conduct finished product testing, measure the acoustic performance of the door body using the reverberation room method, detect that the fire resistance performance meets the 1.5-hour fire resistance rating, and conduct a switch durability test of no less than 100,000 times.

[0031] Among them, the sound transmission loss theory specifically refers to the quantitative description of the energy attenuation when sound waves propagate from one medium to another, and calculates the sound energy transfer characteristics in a multi-layer structure through the mass law, resonance effect, and coincidence effect.

[0032] Among them, the weighted directed graph specifically refers to a mathematical model used to represent the sound transmission relationship between material layers, where nodes represent different material layers and edge weights represent the sound energy transfer efficiency.

[0033] Among them, the minimum cut maximum flow algorithm specifically refers to a graph theory optimization algorithm used to solve network flow problems, and is used to find the optimal material combination scheme in the design of sound insulation doors.

[0034] Among them, the firestone slab specifically refers to a high-density fireproof board composed of calcium silicate and fiber materials, with excellent sound insulation characteristics and fire resistance performance.

[0035] Among them, the graphene composite board specifically refers to a new composite material formed by mixing graphene materials with a polymer matrix, with the characteristics of light weight, high sound insulation performance, and high fire protection level.

[0036] Among them, the tongue-and-groove joint specifically refers to the concave-convex structure designed on the contact surface between the door leaf and the door frame, forming a labyrinth acoustic barrier to block the direct propagation path of sound waves.

[0037] Among them, the reverberation room method specifically refers to placing the door body to be measured in a standard reverberation room, calculating the sound transmission loss by measuring the sound pressure level difference between the sound source room and the receiving room, and evaluating the sound insulation performance index Rw + C value.

[0038] The acoustic transmission matrix equations are used to replace the finite element model for the structural design and optimization of sound insulation doors, including material impedance equations, interface transmission equations, overall transmission equations, and acoustic evaluation equations;

[0039] The material impedance equations are used to calculate the acoustic characteristic parameters of each layer of materials. The inputs include material density, Young's modulus, Poisson's ratio, material thickness, and internal loss factor, and the outputs are the material characteristic impedance value and wave number;

[0040] The interface transmission equations are used to calculate the propagation characteristics of sound waves at the interface between two materials. The inputs include the incident angle, incident energy, characteristic impedances of the front and rear materials, interface bonding stiffness, and interface thickness, and the outputs are the reflection coefficient and transmission coefficient;

[0041] The overall transmission equations are used to integrate the acoustic transmission behaviors of multi-layer structures. The inputs include the transmission matrices of each layer of materials, the interface transmission matrices between layers, the total thickness of the structure, and boundary conditions, and the output is the total system transmission matrix;

[0042] The acoustic evaluation equations are used to quantitatively calculate the sound insulation performance index. The inputs include the total system transmission matrix, standard frequency range, reference sound pressure level, and environmental correction factor, and the outputs are the sound transmission loss value and the weighted sound insulation amount Rw + C value.

[0043] Among them, the structures of each layer of the door body refer to a multi-layer composite structure composed of high-strength carbon steel plates, flame-retardant high-density sound insulation felts, and intermediate layer sound insulation materials. Among them, the high-strength carbon steel plates are located in the outermost layer, the flame-retardant high-density sound insulation felts are located in the second and fourth layers, and the intermediate layer sound insulation materials are located in the third layer.

[0044] Among them, the material density refers to the mass of the material per unit volume, which is obtained through experimental measurement and is used to calculate the material impedance equation. The Young's modulus refers to the elastic parameter of the material, which represents the ability of the material to resist elastic deformation, is obtained through material mechanics tests, and is used to calculate the material impedance equation. The Poisson's ratio refers to the ratio of the transverse strain to the axial strain of the material in the tensile state, is obtained through material mechanics tests, and is used to calculate the material impedance equation. The internal loss factor refers to the parameter of the conversion of acoustic energy into heat energy inside the material, is obtained through acoustic tests, and is used to calculate the material impedance equation. The material characteristic impedance value refers to the resistance characteristic of the sound wave propagating in the material, is calculated from the material impedance equation, and is used as the input for the interface transmission equation. The wave number refers to the number of cycles of the sound wave oscillation per unit length, is calculated from the material impedance equation, and is used as the input for the interface transmission equation. The incident angle refers to the angle at which the sound wave impinges on the interface, is determined through acoustic analysis, and is used as the input for the interface transmission equation. The incident energy refers to the magnitude of the energy carried by the incident sound wave, is determined through the source parameters, and is used as the input for the interface transmission equation. The interface bonding stiffness refers to the stiffness parameter of the bonding interface between two materials, is obtained through material bonding force tests, and is used as the input for the interface transmission equation. The interface thickness refers to the actual thickness of the bonding layer between two materials, is obtained through microstructure analysis, and is used as the input for the interface transmission equation. The reflection coefficient refers to the ratio of the reflected energy to the incident energy of the sound wave at the interface, is calculated from the interface transmission equation, and is used as the input for the overall transmission equation. The transmission coefficient refers to the ratio of the transmitted energy to the incident energy of the sound wave at the interface, is calculated from the interface transmission equation, and is used as the input for the overall transmission equation. The transmission matrix of each layer of material refers to the matrix that describes the propagation characteristics of the sound wave in a single material layer, is calculated based on the material characteristic impedance value and the wave number, and is used as the input for the overall transmission equation. The interlayer interface transmission matrix refers to the matrix that describes the propagation characteristics of the sound wave at the material interface, is calculated based on the reflection coefficient and the transmission coefficient, and is used as the input for the overall transmission equation. The total thickness of the structure refers to the overall thickness of the multi-layer structure of the door body, is determined through design parameters, and is used as the input for the overall transmission equation.

[0045] Among them, the boundary condition refers to the constraint condition of the sound wave at the structure boundary, is determined through acoustic boundary theory, and is used as the input for the overall transmission equation. The total system transmission matrix refers to the matrix that describes the propagation characteristics of the sound wave in the entire multi-layer structure, is calculated from the overall transmission equation, and is used as the input for the acoustic evaluation equation.

[0046] Among them, the standard frequency range refers to the frequency interval for evaluating the sound insulation performance, which is the 16 one-third octave bands from 100 Hz to 3150 Hz specified in the GB / T 19889.3 standard and is used as the input for the acoustic evaluation equation. The reference sound pressure level refers to the reference sound pressure level for evaluating the sound insulation performance, which is the reference value specified in the GB / T 19889.1 standard and is used as the input for the acoustic evaluation equation. The environmental correction factor refers to the correction parameter considering the actual environmental impact, which is obtained through on-site acoustic testing and is used as the input for the acoustic evaluation equation. The transmission loss value refers to the decibel value of the energy attenuation of the sound wave after passing through the structure, which is calculated by the acoustic evaluation equation and is used to evaluate the sound insulation performance of the door body. The weighted sound insulation quantity Rw + C value refers to the comprehensive index of the sound insulation performance obtained according to the weighted calculation method specified in the GB / T 19889.3 standard, which is calculated by the acoustic evaluation equation and is used to evaluate whether the door body meets the requirements of the studio GY / T 5086 - 2012 standard. The fire resistance rating refers to the classification of the fire resistance ability of building materials or components specified in the GB 50222 standard and is used to evaluate the fire prevention performance of the door body.

[0047] The specific implementation manners of the above steps are described in detail below. Specific implementation manner of step S01: When designing the acoustic isolation parameters, first establish a mathematical model of a multi-layer structure based on the transmission loss theory. This model decomposes the propagation process of sound waves through the multi-layer structure into three sub-processes: incidence, reflection, and transmission, and calculates the sound energy transfer characteristics of each frequency band through the mass law, resonance effect, and coincidence effect. Specifically in implementation, first collect the basic parameters of each candidate material, including density (ρ), Young's modulus (E), Poisson's ratio (μ), and internal loss factor (η). The density reference values are 7850 kg / m 3 for steel plates, 160 kg / m 3 for sound insulation felts, and 1800 kg / m 3 for fire slate; then construct a weighted directed graph model of each layer structure of the door body, where the nodes represent different material layers, and the weight of the edge represents the sound energy transfer efficiency. The weight value range is usually between 0 and 1, and the closer it is to 0, the better the sound insulation effect; then apply the minimum cut maximum flow algorithm to solve the minimum cut set of this graph to determine the optimal solution of the material combination. This algorithm finds the augmenting path through the Ford - Fulkerson method until no augmenting path can be found. Finally, the minimum cut value corresponds to the optimal sound insulation scheme; finally, optimize the thickness parameters of each layer of material through the acoustic transmission matrix equations. The thickness range of the steel plate is 1.2 - 2.0 mm, the thickness range of the sound insulation felt is 15 - 25 mm, and the thickness range of the intermediate sound insulation material is 8 - 15 mm. Iterative calculation is performed until the Rw + C value of the overall sound insulation performance meets the studio standard requirement of not less than 45 dB. The purpose of this step is to determine the optimal door body structure parameters through theoretical calculation and provide accurate technical basis for subsequent production.

[0048] Specific implementation of step S02: When cutting high-strength carbon steel plate as the outer layer of the door, first select Q345B high-strength carbon steel plate according to the design drawing, with a yield strength of not less than 345 MPa; then use a numerical control laser cutting device for precise cutting. Set the laser power to 2500 - 3000 W, control the cutting speed at 15 - 20 m / min, and monitor the cutting accuracy in real time through a closed-loop control system to ensure that the dimensional tolerance is controlled within ±0.5 mm; then perform surface treatment on the steel plate, including sandblasting and rust removal. Select emery as the sandblasting material, control the particle size at 80 - 100 mesh, and the sandblasting pressure at 0.6 - 0.8 MPa. After treatment, the surface roughness reaches Ra3.2 μm; then perform phosphating treatment, use a zinc-based phosphating solution, control the concentration at 4.5 - 5.5%, the treatment temperature at 50 - 60 °C, and the treatment time at 8 - 12 minutes to form a phosphating film with a thickness of 8 - 12 μm; finally, spray epoxy primer, control the paint film thickness at 40 - 60 μm, the curing temperature at 150 - 180 °C, and the curing time at 30 - 40 minutes. The function of this step is to prepare the outer layer steel plate of the door with high strength and high durability, providing the basic structural support and fire barrier for the entire sound insulation door.

[0049] Specific implementation of step S03: When preparing the flame-retardant high-density sound insulation felt, first select polyester fiber with a diameter of 12 - 15 μm as the base material, and control the fiber length at 38 - 51 mm; then mix the polyester fiber and the phosphorus-based flame retardant according to a mass ratio of 4:1. Select a phosphate compound with a phosphorus content of not less than 20% as the flame retardant; then use the air-laid technology to prepare the primary fiber web, control the web-forming speed at 8 - 12 m / min, and control the coefficient of variation of the web weight uniformity within ±5%; then use the hot pressing and forming process, set the hot pressing temperature at 210 - 230 °C, control the pressure at 2.5 - 3.5 MPa, and the hot pressing time at 3 - 5 minutes; finally, perform precise cutting and shaping, control the finished product density within 150 - 200 kg / m 3 range, and control the thickness tolerance within ±0.5 mm. The purpose of this step is to prepare the key functional material with both sound insulation and flame retardant properties. The three-dimensional spatial structure of the fiber forms a microscopic channel for acoustic energy consumption, while the phosphorus-based flame retardant can form a charred layer at high temperatures to block oxygen and provide fire protection performance.

[0050] Specific implementation of step S04: When processing the intermediate layer sound insulation material, first select a suitable material according to the calculation results of acoustic parameters. Fire slate or graphene composite board can be selected. The density range of fire slate is 1600 - 2000 kg / m 3 , and the density range of graphene composite board is 1200 - 1500 kg / m 3; Then, a high-precision numerically controlled water jet is used for cutting. The water pressure is controlled within 380 - 420 MPa, and the cutting speed is 200 - 300 mm / min to ensure the cutting accuracy is within the range of ±0.3 mm. Next, a CNC precision milling machine is used to chamfer the edges of the material. The chamfer angle is designed to be 45°, and the chamfer width is 3 - 5 mm. Finally, surface treatment is carried out by polishing with fine sandpaper (320 mesh) to ensure that the surface roughness Ra value does not exceed 1.6 μm. The purpose of this step is to prepare the core sound insulation material for the middle layer. The fire slate provides good sound insulation and fire protection performance through its porous structure and high-density characteristics, while the graphene composite board uses the two-dimensional nanostructure of graphene and the polymer network to provide a lightweight and high-strength sound insulation barrier. Both materials can effectively block the propagation of medium and low-frequency sound waves.

[0051] Specific implementation method of step S05: When assembling the door body using the lamination process, first clean the surfaces of each layer of material, and wipe off the surface oil stains and dust with anhydrous ethanol. Then, stack the high-strength carbon steel plate, flame-retardant high-density sound insulation felt, middle-layer sound insulation material, flame-retardant high-density sound insulation felt, and high-strength carbon steel plate in sequence according to the design to form a five-layer composite structure of "steel-felt-core-felt-steel". Next, evenly coat epoxy structural adhesive between each layer. The thickness of the adhesive layer is controlled within 0.2 - 0.3 mm, and the adhesive coverage rate reaches over 95%. The selected epoxy structural adhesive has a shear strength of not less than 25 MPa and a tensile strength of not less than 15 MPa. Subsequently, place the laminated structure into a hydraulic press for pressing. The pressure is controlled within 1.8 - 2.2 MPa, and maintain a constant temperature environment of 25 - 30 °C during pressing to ensure uniform curing of the adhesive layer. Finally, carry out curing treatment. The curing time is 24 - 48 hours, and check the pressure value every 8 hours during this period to ensure uniform pressure. The purpose of this step is to effectively combine the functional layer materials into an integral door body structure, achieve tight bonding between layers through the lamination process, avoid cavity resonance, form a gradient change in acoustic impedance, and improve the overall sound insulation performance.

[0052] Specific implementation of step S06: When the door frame adopts a three - channel rabbet design, first select a carbon steel plate with a thickness of not less than 2.5 mm as the door frame base material; then design a three - channel staggered rabbet structure according to the principle of acoustic maze. The depth of each rabbet is designed to be 8 - 12 mm, the width of the rabbet is 15 - 20 mm, and the staggering distance between adjacent rabbets is 5 - 8 mm; then use a numerical control bending machine to precisely bend the steel plate, and control the bending angle tolerance within the range of ±0.5°, and the bending radius within 1.5 times the material thickness; subsequently, use a precision milling machine to process the rabbet surface to ensure that the flatness error of the rabbet surface does not exceed 0.1 mm / m, and the perpendicularity error does not exceed 0.2 mm / m; finally, perform surface treatment and painting, using the same process flow as the door body steel plate. The function of this step is to manufacture a door frame with an acoustic maze structure. The three - channel rabbet design forms a Z - shaped sound propagation path based on the principles of sound wave refraction and scattering, increases the sound wave propagation distance, and significantly attenuates the sound energy through multiple reflections and scatterings, thereby improving the overall sound insulation performance.

[0053] Specific implementation of step S07: When installing a special sealing strip on the rabbet surface, first select a sealing strip made of high - temperature resistant silicone rubber. The Shore A hardness of the material is 65 - 75 degrees, the temperature resistance range is - 40 - 280 °C, and the oxygen index is not less than 28%; then cut the sealing strip to the required specifications, and the cutting length is 2 - 3% longer than the length of the installation groove to ensure an appropriate pre - tightening force after installation; then clean the surface of the installation groove, and use anhydrous ethanol to wipe off oil stains and dust; subsequently, evenly coat the bottom of the installation groove with a rubber strip adhesive, and select an organosilicon - based adhesive for the adhesive, with a shear bonding strength of not less than 1.2 MPa; finally, press the sealing strip into the installation groove to ensure that the compression rate is designed within the range of 15% - 20%. This compression rate can provide sufficient sealing pressure when the door body is closed, and at the same time will not cause excessive deformation and damage to the rubber strip. The purpose of this step is to achieve an airtight seal between the door body and the door frame, block the path of sound wave propagation through the gap, and at the same time provide smoke - proof and fire - proof performance. The material properties and compression rate design of the sealing strip are the keys to ensuring the sealing effect.

[0054] Specific implementation of step S08: When assembling the hardware, first select a suitable heavy-duty self-closing hinge according to the weight of the door body. The load-bearing capacity of a single hinge is not less than 80 kg, and usually 3 to 4 hinges are configured for the door body. Then install the multi-point locking device. The distance between the lock points is designed to be 300 to 400 mm, the protruding length of the lock tongue is not less than 20 mm, and the lock with a fire protection level not lower than Class B is selected. Next, install the pressure regulator with a pressure adjustment range of 50 to 200 N, which can be accurately adjusted according to the size and weight of the door body. Subsequently, adjust the gap between the door leaf and the door frame. By adjusting the position and angle of the hinge, the parallelism error between the door leaf and the door frame does not exceed 1 mm / m, and the gap is evenly controlled within the range of 2 to 3 mm. Finally, conduct the balance test of the door body opening and closing. Under the action of the door closer, the time from the 80° opening position to the fully closed state is controlled within 4 to 7 seconds. The function of this step is to install a high-performance door body operating mechanism to ensure that the sound insulation door has good performance and convenient operation. At the same time, precise gap control between the door frame and the door leaf is a necessary condition for achieving an ideal sound insulation effect.

[0055] Specific implementation of step S09: When conducting the finished product test, first measure the acoustic performance of the door body by the reverberation room method in accordance with the standard of GB / T 19889.3. The test signal generated in the sound source room is pink noise with a sound pressure level of 100 ± 3 dB, and the measurement frequency range is 100 to 3150 Hz, a total of 16 one-third octave bands. Then calculate the sound transmission loss values of each frequency band, and calculate the weighted sound insulation quantity Rw + C value according to the standard. The qualified standard is that the Rw + C value of the studio door body is not less than 45 dB. Next, conduct the fire performance test and carry out the fire resistance test in accordance with the standard of GB 12955. The flame temperature is controlled according to the standard time-temperature curve, and it is required to reach a fire resistance rating of 1.5 hours, that is, under the standard fire conditions for 90 minutes, the door body does not have a penetrating failure, and the highest temperature on the back fire side does not exceed the specified limit value. Subsequently, conduct the airtightness test. Under the condition of a pressure difference of 50 Pa, the air leakage per unit door seam length does not exceed 1.5 m 3 / h·m; Finally, conduct the opening and closing durability test, continuously open and close the test at a frequency of 6 to 10 times per minute for not less than 100,000 times. After the test, the change of each functional index of the door body does not exceed 10%. The purpose of this step is to comprehensively verify the performance indicators of the finished product sound insulation door to ensure that it meets the technical requirements and usage standards of the studio professional fireproof and sound insulation door.

[0056] The following details the mathematical models or calculation processes involved in the present invention.

[0057] The material impedance equation is used to calculate the acoustic characteristic parameters of each layer of material, and its expression is:

[0058]

[0059] In the formula, Z i$Z_i$ is the characteristic impedance value of the $i$-th layer of material, with the unit of Pa·s / m; $\rho$ i is the density of the $i$-th layer of material, with the unit of kg / m 3 ; $c$ i is the propagation speed of sound waves in the $i$-th layer of material, with the unit of m / s; $j$ is the imaginary unit; $\eta$ i is the internal loss factor of the $i$-th layer of material, dimensionless; $k$ i is the wave number in the $i$-th layer of material, that is, the number of wave cycles per unit distance, with the unit of Rad / m; $\omega$ is the angular frequency, with the unit of Rad / s. In the above equation, according to the basic definition of the wave number, the wave number where $\omega$ is the angular frequency (radians / second) and $c$ is the wave speed (meters / second); the complex term modifies the wave number to account for energy dissipation (damping) in the material, which also varies with frequency.

[0060] Among them, the parameter acquisition method is:

[0061] $\rho$ i is obtained through experimental measurement. It is measured using a standard density tester in accordance with GB / T 1033. The density range of high-strength carbon steel plates is 7800 - 7900 kg / m 3 , the density range of flame-retardant high-density sound insulation felt is 150 - 200 kg / m 3 , the density range of firestone slabs is 1600 - 2000 kg / m 3 , the density range of graphene composite plates is 1200 - 1500 kg / m 3 .

[0062] $c$ i is obtained through experimental measurement. It is measured using the ultrasonic velocity measurement method in accordance with the ISO 10848 standard. The sound speed range of high-strength carbon steel plates is 5100 - 5200 m / s, the sound speed range of flame-retardant high-density sound insulation felt is 300 - 500 m / s, the sound speed range of firestone slabs is 2000 - 2500 m / s, and the sound speed range of graphene composite plates is 1500 - 2000 m / s.

[0063] $\eta$ i is obtained through resonance measurement. It is measured in accordance with the ASTM E756 standard. The internal loss factor range of high-strength carbon steel plates is 0.001 - 0.005, the internal loss factor range of flame-retardant high-density sound insulation felt is 0.2 - 0.4, the internal loss factor range of firestone slabs is 0.05 - 0.15, and the internal loss factor range of graphene composite plates is 0.1 - 0.2.

[0064] The interface transmission equation is used to calculate the propagation characteristics of sound waves at the interface of two materials, and its expression is:

[0065]

[0066] In the formula, R i，i+1 is the reflection coefficient at the interface between the i-th layer and the (i + 1)-th layer, dimensionless; T i，i+1 is the transmission coefficient at the interface between the i-th layer and the (i + 1)-th layer, dimensionless; Z i and Z i+1 are the characteristic impedance values of the materials of the i-th layer and the (i + 1)-th layer respectively, with the unit of Pa·s / m; K i，i+1 is the interface bonding stiffness, with the unit of N / m 3 ; d i，i+1 is the interface thickness, with the unit of m; ω is the angular frequency, with the unit of Rad / s.

[0067] The above equation considers that the interface between materials is not completely rigid - it has compliance (the reciprocal of stiffness). This compliance creates a spring-like behavior that is frequency-dependent; the term represents a frequency-dependent phase shift. At certain frequencies, this can produce a resonance effect that significantly changes the way sound propagates.

[0068] Among them, the parameter acquisition method is as follows:

[0069] K i，i+1 is obtained through interface shear testing, using a material testing machine to conduct tests in accordance with ASTM D905 standard. The bonding stiffness range of the interface between the steel plate and the sound insulation felt is 1×10 9 to 5×10 9 N / m 3 , and the bonding stiffness range of the interface between the sound insulation felt and the intermediate layer sound insulation material is 5×10 8 to 2×10 9 N / m 3 .

[0070] d i，i+1 is obtained by observing and measuring through a scanning electron microscope. The interface thickness range is usually 0.01 - 0.1 mm.

[0071] The overall transmission equation is used to integrate the acoustic transmission behavior of a multi-layer structure, and its matrix expression is:

[0072]

[0073] In the formula, p t and v t are the sound pressure and particle velocity of the transmitted sound wave respectively, with the units of Pa and m / s; p0 and v0 are the sound pressure and particle velocity of the incident sound wave respectively, with the units of Pa and m / s; T i is the transmission matrix of the i-th layer material; k i is the wave number of the i-th layer material, with the unit of Rad / m; di is the thickness of the i-th layer of material, with the unit of m; Z i is the characteristic impedance value of the i-th layer of material, with the unit of Pa·s / m; n is the number of material layers.

[0074] Among them, the parameter acquisition method is:

[0075] d i is determined by the design parameters. The thickness range of the high-strength carbon steel plate is 1.2 - 2.0 mm, the thickness range of the flame-retardant high-density sound insulation felt is 15 - 25 mm, and the thickness range of the intermediate layer sound insulation material is 8 - 15 mm.

[0076] The complete overall transfer matrix considering the interlayer interface effect is:

[0077] T total = T1·I 1，2 ·T2·I 2，3 ·...·T n-1 ·I n-1，n ·T n ;

[0078]

[0079] In the formula, T total is the total system transfer matrix; I i，i+1 is the transfer matrix at the interface between the i-th layer and the i + 1-th layer; R i，i+1 is the interface reflection coefficient; T i，i+1 is the interface transmission coefficient.

[0080] The acoustic evaluation equation is used to quantitatively calculate the sound insulation performance index, and its expression is:

[0081]

[0082] In the formula, TL is the transmission loss value, with the unit of dB; Z0 and Z n are the characteristic impedances of the media on the incident side and the transmission side respectively, with the unit of Pa·s / m; T total，ij is the element in the i-th row and j-th column of the total system transfer matrix; R w + C is the weighted sound insulation amount, with the unit of dB; L i is the reference sound pressure level in the i-th frequency band, with the unit of dB; TL i is the transmission loss value in the i-th frequency band, with the unit of dB; W i is the weighting factor in the i-th frequency band, dimensionless.

[0083] Among them, the parameter acquisition method is:

[0084] L iDetermined according to the reference values specified in the GB / T 19889.1 standard, 16 one-third octave frequency bands with a frequency range of 100 Hz to 3150 Hz.

[0085] W i Determined according to the frequency weighting curve specified in the GB / T 19889.3 standard, with different weighting values corresponding to different frequency bands.

[0086] In step S01, the minimum cut maximum flow algorithm is also applied to determine the optimal solution of the material combination. This algorithm is expressed based on graph theory as follows:

[0087] min∑ (u，v)∈s c(u, v);

[0088] s.t. S is a cut set;

[0089] In the formula, c(u, v) is the capacity of the edge (u, v), representing the sound energy transfer efficiency; S is a cut set, representing a set of edges. After removing these edges, the source point and the sink point are no longer connected; E is the edge set.

[0090] The iterative process of the Ford-Fulkerson method is expressed as:

[0091] f(u, v) = f(u, v) + Δ;

[0092] f(v, u) = f(v, u) - Δ;

[0093] In the formula, f(u, v) is the flow on the edge (u, v); Δ is the minimum residual capacity on the augmenting path, and the calculation formula is:

[0094] Δ = min (u，v)∈P (c(u, v) - f(u, v));

[0095] P is the augmenting path.

[0096] The maximum flow minimum cut theorem ensures that when no augmenting path can be found, the value of the maximum flow is equal to the capacity of the minimum cut, that is:

[0097] max∑ v：(s，v)∈E f(s, v) = min∑ (u，v)∈S c(u, v);

[0098] In the formula, s is the source point, representing the sound source; v is the node adjacent to the source point; f(s, v) is the flow from the source point to the node v; S is the minimum cut set.

[0099] The construction principle and significance of the above equations are as follows:

[0100] The material impedance equation is based on wave theory and takes into account the elastic and damping properties of materials. The introduction of the wave number and characteristic impedance in complex form is to describe the propagation characteristics of waves in lossy materials, where the real part represents the propagation characteristics and the imaginary part represents the attenuation characteristics. The internal loss factor η i As a measure of the damping performance of materials, it directly affects the attenuation rate of sound energy in materials.

[0101] The interface transmission equation is based on the continuity condition of sound waves at the interface, but innovatively introduces the interface bonding stiffness and interface thickness parameters, which are often ignored in traditional acoustic theory. This equation considers the influence of imperfect interface bonding on sound wave propagation through the complex term in the denominator, making it more in line with the physical characteristics of material interfaces in practical engineering.

[0102] The overall transmission matrix integrates the transmission characteristics of each layer of material in a cascaded manner. The transmission matrix of each layer of material is based on the analytical solution of sound wave propagation in a homogeneous medium. The innovation lies in considering the interlayer interface effect, and through the interface transmission matrix I i，i+1 It corrects the deficiencies of the traditional transmission matrix method and improves the calculation accuracy. The advantage of the transmission matrix method is its high calculation efficiency, which can handle complex multi-layer structures without solving the complete wave equation.

[0103] The acoustic evaluation equation is based on the principle of energy conservation and calculates the ratio of incident sound energy to transmitted sound energy. This equation directly calculates the transmission loss through the elements of the overall transmission matrix, avoiding intermediate steps and improving the calculation efficiency. The weighted sound insulation R w The introduction of +C conforms to international standards, takes into account the sensitivity differences of the human ear to sounds of different frequencies, and makes the evaluation results more in line with subjective feelings.

[0104] The application of the minimum cut maximum flow algorithm in sound insulation design is an innovation point. It abstracts the sound energy transmission path as a network flow problem and determines the key sound insulation positions by finding the "bottleneck" (minimum cut). The advantage of this algorithm is that it can handle the sound transmission network with complex topological structures and find the global optimal solution, rather than relying solely on empirical judgment.

[0105] Generally speaking, the construction of these equations takes into account the complete physical process of sound wave propagation in multi-layer structures, including material properties, interface effects, overall structural response, and auditory perception characteristics, forming a systematic theoretical framework, providing a scientific basis for the design of sound insulation doors, and having higher accuracy and efficiency compared with traditional design methods.

[0106] Specifically, the principle of the present invention is as follows: The core technical principle of the present invention is based on the acoustic transfer matrix theory, which abstracts the acoustic wave propagation process in a complex multi-layer structure into a series of matrix operations, thereby accurately describing the transfer characteristics of acoustic energy between different material interfaces. Specifically, the present invention adopts four key equations: the material impedance equation, the interface transfer equation, the overall transfer equation, and the acoustic evaluation equation, forming a complete theoretical system.

[0107] The material impedance equation calculates the characteristic impedance value and wave number of the material by inputting parameters such as material density, Young's modulus, Poisson's ratio, etc., thereby quantifying the acoustic characteristics of the material. The interface transfer equation, based on these characteristic parameters and combined with factors such as the incident angle and interface bonding stiffness, calculates the reflection coefficient and transmission coefficient of the acoustic wave at the material interface, describing the distribution law of acoustic energy at the interface. These two equations solve the problem in the traditional technology that the acoustic behavior of multi-layer materials cannot be accurately predicted.

[0108] The present invention innovatively represents each layer structure of the door body as a weighted directed graph, where the nodes represent different material layers and the edge weights represent the acoustic energy transfer efficiency. By applying the minimum cut maximum flow algorithm, it is possible to find the optimal material combination scheme with the best sound insulation performance under the limited material selection and thickness constraint conditions. This optimization method effectively balances the conflicting requirements of sound insulation performance and fire resistance performance, and at the same time considers the production cost and process feasibility.

[0109] In terms of structural design, the present invention adopts the "rigid-soft-rigid" sandwich structure principle, uses a damping layer (flame-retardant high-density sound insulation felt) to absorb and convert acoustic energy, and at the same time creates a reflection interface through the combination of different acoustic impedance materials (high-strength carbon steel plate and composite plate of firestone or graphene), forming an "acoustic trap" to effectively block the propagation of acoustic waves in all frequency bands. The three rabbet designs are based on the acoustic wave maze principle, forcing the acoustic waves to undergo multiple reflections and attenuations, thereby significantly improving the edge sealing performance. The combination of these theories and structural designs enables the present invention to simultaneously meet the dual requirements of sound insulation and fire resistance, and solves the core technical problems.

[0110] The following provides a specific embodiment 1 of the present invention, and the specific implementation manners of each step in this embodiment 1 are described in detail as follows.

[0111] The specific implementation manner of step S01 is to perform acoustic isolation parameter design. First, a mathematical model of the multi-layer structure based on the sound transmission loss theory is established. This model decomposes the propagation process of acoustic waves through the multi-layer structure into three sub-processes: incidence, reflection, and transmission, and calculates the acoustic energy transfer characteristics in each frequency band through the mass law, resonance effect, and coincidence effect. Specifically in implementation, first collect the basic parameters of each candidate material, including density (ρ), Young's modulus (E), Poisson's ratio (μ), and internal loss factor (η). Based on these parameters, calculate the characteristic impedance value and wave number of each layer of material, and its expression is: Wherein, Z i is the characteristic impedance value of the i-th layer of material, with the unit of Pa·s / m; ρ i is the density of the i-th layer of material, with the unit of kg / m 3 ; c i is the propagation speed of sound waves in the i-th layer of material, with the unit of m / s; j is the imaginary unit; η i is the internal loss factor of the i-th layer of material, dimensionless; k i is the wave number in the i-th layer of material, with the unit of Rad / m; ω is the angular frequency, with the unit of Rad / s. Then, a weighted directed graph model of each layer structure of the door body is constructed, where the nodes represent different material layers, and the weight of the edge represents the sound energy transfer efficiency. The weight value range is usually between 0 and 1, and the closer it is to 0, the better the sound insulation effect. The minimum cut maximum flow algorithm is applied to solve the minimum cut set of this graph to determine the optimal solution of the material combination. The objective function of this algorithm is: min∑ (u，v)∈s c(u, v); s.t. S is the cut set; wherein, c(u, v) is the capacity of the edge (u, v), representing the sound energy transfer efficiency; S is the cut set, representing a set of edges. After removing these edges, the source point and the sink point are no longer connected; E is the edge set. The Ford-Fulkerson method is used to find the augmenting path, and its iterative process is expressed as: f(u, v) = f(u, v) + Δ; f(v, u) = f(v, u) - Δ; wherein, f(u, v) is the flow on the edge (u, v); Δ is the minimum residual capacity on the augmenting path, calculated as: Δ = min (u，v)∈P (c(u, v) - f(u, v)); P is the augmenting path. Finally, the thickness parameters of each layer of material are optimized through the acoustic transmission matrix equations. Calculate the interface transmission coefficient: Wherein, R i，i+1 is the interface reflection coefficient; T i，i+1 is the interface transmission coefficient; K i，i+1 is the interface bonding stiffness; d i，i+1 is the interface thickness. Construct the overall transmission matrix: The complete matrix considering the interface effect is: T total = T1·I 1，2 ·T2·I 2，3 ·...·T n-1 ·I n-1，n ·T n ; Finally, calculate the sound insulation performance index: W i ; wherein, TL is the transmission loss value; R w +C is the weighted sound insulation amount; L iis the reference sound pressure level; W i is the weighting factor. Through iterative calculations, the thickness of each layer of material is optimized until the overall sound insulation performance reaches an Rw + C value not lower than 45 dB, which meets the requirements of the studio standard. The purpose of this step is to determine the optimal door structure parameters through theoretical calculations, providing accurate technical basis for subsequent production.

[0112] The specific implementation of step S02 is to cut high-strength carbon steel plates as the outer layer of the door. First, select Q345B grade high-strength carbon steel plates according to the design drawings, with a yield strength not lower than 345 MPa; then use numerical control laser cutting equipment for precise cutting. Set the laser power to 2500 - 3000 W, control the cutting speed at 15 - 20 m / min, and monitor the cutting accuracy in real time through a closed-loop control system to ensure that the dimensional tolerance is controlled within ±0.5 mm; then perform surface treatment on the steel plate, including sandblasting and rust removal treatment. Select emery as the sandblasting material, control the particle size at 80 - 100 mesh, and the sandblasting pressure at 0.6 - 0.8 MPa. After treatment, the surface roughness reaches Ra3.2 μm; then perform phosphating treatment, use zinc-based phosphating solution, control the concentration at 4.5 - 5.5%, the treatment temperature at 50 - 60 °C, and the treatment time at 8 - 12 minutes to form a phosphating film with a thickness of 8 - 12 μm; finally, spray epoxy primer, control the paint film thickness at 40 - 60 μm, the curing temperature at 150 - 180 °C, and the curing time at 30 - 40 minutes. The function of this step is to prepare the outer layer steel plate of the door with high strength and high durability, providing the basic structural support and fire barrier for the entire sound insulation door.

[0113] The specific implementation of step S03 is to prepare a flame-retardant high-density sound insulation felt. First, select polyester fibers with a diameter of 12 - 15 μm as the base material, and control the fiber length at 38 - 51 mm; then mix the polyester fibers with a phosphorus-based flame retardant in a mass ratio of 4:1. Select phosphate ester compounds with a phosphorus content not lower than 20% as the flame retardant; then use the air-laid technology to prepare the primary fiber web, control the web-forming speed at 8 - 12 m / min, and control the coefficient of variation of web weight uniformity within ±5%; then use the hot pressing and forming process, set the hot pressing temperature at 210 - 230 °C, control the pressure at 2.5 - 3.5 MPa, and the hot pressing time at 3 - 5 minutes; finally, perform precise cutting and shaping, control the finished product density within 150 - 200 kg / m 3 range, and control the thickness tolerance within ±0.5 mm. The purpose of this step is to prepare the key functional material with both sound insulation and flame retardant properties. The three-dimensional spatial structure of the fibers forms microscopic channels for the consumption of sound wave energy, while the phosphorus-based flame retardant can form a carbonized layer at high temperatures to block oxygen and provide fire protection performance.

[0114] The specific implementation of step S04 is to process the intermediate layer sound insulation material. First, select a suitable material according to the calculation results of acoustic parameters. Fire slate or graphene composite board can be selected. The density range of fire slate is 1600 - 2000 kg / m 3 , and the density range of graphene composite board is 1200 - 1500 kg / m 3 ; then use a high-precision CNC water jet for cutting. The water pressure is controlled at 380 - 420 MPa, and the cutting speed is 200 - 300 mm / min to ensure that the cutting accuracy is within the range of ±0.3 mm; then use a CNC precision milling machine to chamfer the edges of the material. The chamfering angle is designed to be 45°, and the chamfering width is 3 - 5 mm; finally, perform surface treatment, and polish with fine sandpaper (320 mesh) to ensure that the surface roughness Ra value does not exceed 1.6 μm. The function of this step is to prepare the core sound insulation material for the intermediate layer. Fire slate provides good sound insulation and fire prevention performance through its porous structure and high-density characteristics, while graphene composite board uses the two-dimensional nanostructure of graphene and polymer network to provide a lightweight and high-strength sound insulation barrier. Both materials can effectively block the propagation of medium and low-frequency sound waves.

[0115] The specific implementation of step S05 is to assemble the door body using a lamination process. First, clean the surfaces of each layer of material, and wipe with anhydrous ethanol to remove surface oil stains and dust; then stack high-strength carbon steel plates, flame-retardant high-density sound insulation felts, intermediate layer sound insulation materials, flame-retardant high-density sound insulation felts, and high-strength carbon steel plates in the designed order to form a five-layer composite structure of "steel-felt-core-felt-steel"; then evenly coat epoxy structural adhesive between each layer. The thickness of the adhesive layer is controlled at 0.2 - 0.3 mm, and the adhesive coverage rate reaches more than 95%. The selected epoxy structural adhesive has a shear strength of not less than 25 MPa and a tensile strength of not less than 15 MPa; then place the laminated structure in a hydraulic press for pressing. The pressure is controlled at 1.8 - 2.2 MPa, and keep the temperature at 25 - 30 °C during pressing to ensure uniform curing of the adhesive layer; finally, perform curing treatment. The curing time is 24 - 48 hours, and check the pressure value every 8 hours during this period to ensure uniform pressure. The purpose of this step is to effectively combine the functional layer materials into an overall door body structure, achieve tight bonding between each layer through the lamination process, avoid cavity resonance, form a gradient change in acoustic impedance, and improve the overall sound insulation performance.

[0116] The specific implementation of step S06 is that the door frame adopts a three - channel rabbet design. First, a carbon steel plate with a thickness of not less than 2.5 mm is selected as the door - frame base material. Then, according to the principle of the acoustic maze, a three - channel staggered rabbet structure is designed. The depth of each rabbet is designed to be 8 - 12 mm, the width of the rabbet is 15 - 20 mm, and the staggered distance between adjacent rabbets is 5 - 8 mm. Next, a numerical - control bending machine is used to precisely bend the steel plate, and the bending - angle tolerance is controlled within the range of ±0.5°, and the bending radius is controlled within 1.5 times the material thickness. Subsequently, a precision milling machine is used to process the rabbet surface to ensure that the flatness error of the rabbet surface does not exceed 0.1 mm / m and the perpendicularity error does not exceed 0.2 mm / m. Finally, surface treatment and painting are carried out, adopting the same technological process as the door - body steel plate. The function of this step is to manufacture a door frame with an acoustic - maze structure. The three - channel rabbet design is based on the principles of sound - wave refraction and scattering, forming a Z - shaped sound - propagation path, increasing the sound - wave propagation distance, and significantly attenuating the sound energy through multiple reflections and scatterings, thereby improving the overall sound - insulation performance.

[0117] The specific implementation of step S07 is to install a special sealing strip on the rabbet surface. First, a sealing strip made of high - temperature - resistant silicone rubber is selected. The Shore A hardness of the material is 65 - 75 degrees, the temperature - resistance range is - 40 - 280 °C, and the oxygen index is not less than 28%. Then, the sealing strip is cut to the required specifications, and the cutting length is 2 - 3% longer than the length of the installation groove to ensure an appropriate pre - tightening force after installation. Next, the surface of the installation groove is cleaned, and anhydrous ethanol is used to wipe off oil stains and dust. Subsequently, the rubber - strip adhesive is evenly coated on the bottom of the installation groove. The adhesive selected is a silicone - based adhesive, and the shear - bonding strength is not less than 1.2 MPa. Finally, the sealing strip is pressed into the installation groove to ensure that the compression ratio is designed within the range of 15% - 20%. This compression ratio can provide sufficient sealing pressure when the door body is closed, and at the same time, it will not cause excessive deformation and damage to the sealing strip. The purpose of this step is to achieve the airtight closure between the door body and the door frame, block the path of sound - wave propagation through the gap, and at the same time provide smoke - prevention and fire - prevention performance. The material properties and compression - ratio design of the sealing strip are the keys to ensuring the sealing effect.

[0118] The specific implementation of step S08 is to assemble the hardware. First, select suitable heavy-duty self-closing hinges according to the weight of the door body. The load-bearing capacity of a single hinge is not less than 80 kg, and usually 3 to 4 hinges are configured for the door body. Then install the multi-point locking device. The distance between the lock points is designed to be 300 to 400 mm, the protruding length of the lock tongue is not less than 20 mm, and the lock selected is a lock with a fire protection rating not lower than Class B. Next, install the pressure regulator with a pressure adjustment range of 50 to 200 N, which can be precisely adjusted according to the size and weight of the door body. Subsequently, adjust the gap between the door leaf and the door frame. By adjusting the position and angle of the hinge, the parallelism error between the door leaf and the door frame does not exceed 1 mm / m, and the gap is evenly controlled within the range of 2 to 3 mm. Finally, conduct the door body opening and closing balance test. Under the action of the door closer, the time from the 80° opening position to the fully closed state is controlled within 4 to 7 seconds. The function of this step is to install a high-performance door body operating mechanism to ensure that the sound insulation door has good performance and operational convenience. At the same time, precise gap control between the door frame and the door leaf is a necessary condition for achieving an ideal sound insulation effect.

[0119] The specific implementation of step S09 is to conduct the finished product test. First, measure the acoustic performance of the door body using the reverberation room method in accordance with the GB / T 19889.3 standard. The test signal generated in the sound source room is pink noise with a sound pressure level of 100 ± 3 dB, and the measurement frequency range is 100 to 3150 Hz, a total of 16 one-third octave bands. Then calculate the sound transmission loss values for each frequency band using the aforementioned acoustic evaluation equation: And calculate the weighted sound insulation amount according to the standard: The passing standard is that the Rw + C value of the studio door body is not less than 45 dB. Then conduct the fire resistance performance test. Conduct the fire resistance test in accordance with the GB 12955 standard. The flame temperature is controlled according to the standard time-temperature curve, and it is required to reach a fire resistance rating of 1.5 hours, that is, under the standard fire conditions for 90 minutes, the door body does not suffer from penetrative damage, and the maximum temperature on the back fire side does not exceed the specified limit. Subsequently, conduct the airtightness test. Under the condition of a pressure difference of 50 Pa, the air leakage per unit door seam length does not exceed 1.5 m 3 / h·m. Finally, conduct the opening and closing durability test. Continuously open and close the test at a frequency of 6 to 10 times per minute for not less than 100,000 times. After the test, the change in each functional index of the door body does not exceed 10%. The purpose of this step is to comprehensively verify the performance indicators of the finished product sound insulation door to ensure that it meets the technical requirements and usage standards of the studio professional fireproof sound insulation door.

[0120] Through the implementation of the above nine steps, a professional fireproof and soundproof door suitable for a studio can be produced. This door has excellent sound insulation performance, fireproof performance, and service durability. During the implementation process, the acoustic isolation parameter design (Step S01) is the theoretical basis and core of the entire production method. By establishing a complete acoustic transmission matrix model and applying the minimum cut maximum flow algorithm to determine the optimal material combination, precise technical parameters are provided for the subsequent steps. Material preparation (Steps S02, S03, S04) and structural assembly (Steps S05, S06) are the key links to realize the theoretical design. By strictly controlling various process parameters, the consistency between the actual product and the theoretical design is ensured. The seal system design (Step S07) and the installation of hardware fittings (Step S08) solve the key technical problems in actual use. The final comprehensive test (Step S09) verifies whether the product performance meets the design requirements. This production method based on acoustic theory and computer optimization algorithms has higher sound insulation efficiency, more reliable fireproof performance, and longer service life compared with traditional empirical design methods, and is particularly suitable for the radio and television studio environment with high requirements for acoustic environment and safety.

[0121] To better understand and implement the present invention, Example 2 of a specific application scenario of the present invention is provided below: To verify the effectiveness of the method of the present invention, a complete implementation process was carried out. This example is applied to a newly built recording studio in a national radio and television center, which has strict requirements for sound insulation performance and fire safety.

[0122] First, for the acoustic isolation parameter design, the basic acoustic parameters of various candidate materials were collected, as shown in Table 1:

[0123] Table 1 Basic Parameter Table of Soundproof Door Materials

[0124]

[0125] Based on these parameters, the characteristic impedance values and wave numbers of each material at different frequencies were calculated. Taking the frequency of 500 Hz as an example, the calculation results are shown in Table 2:

[0126] Table 2 Calculation Results of Acoustic Parameters of Materials at 500 Hz Frequency

[0127] Material type <![CDATA[Characteristic impedance (10 7 Pa·s / m)]]> Wave number (Rad / m) High-strength carbon steel plate 4.04-0.004j 0.61+0.0006j Flame-retardant high-density sound insulation felt 0.072-0.012j 6.98+1.12j Fire slate 0.41-0.016j 1.36+0.05j Graphene composite plate 0.24-0.018j 1.74+0.13j

[0128] A weighted directed graph model was used to represent the sound transmission efficiency of different material combinations, and a sound energy transmission network was constructed. Through the minimum cut maximum flow algorithm, the optimal material combination scheme was calculated. After multiple iterative calculations, the final door structure was determined as: 2 mm high-strength carbon steel plate + 1 mm flame-retardant high-density soundproof felt + 45 mm firestone slab + 1 mm flame-retardant high-density soundproof felt + 2 mm high-strength carbon steel plate, with a total thickness of 51 mm and a total weight of about 98 kg / m2 。

[0129] Next, the preparation and processing of each layer of materials were completed in sequence. The high-strength carbon steel plate used Q345B steel, and was cut using a numerically controlled laser cutting equipment with a power of 2800W. The cutting speed was set at 17m / min, and the measured dimensional tolerance was controlled within the range of ±0.3mm. The surface treatment used 90-mesh emery, and the sandblasting pressure was 0.7MPa. The phosphating treatment used a zinc-based phosphating solution with a concentration of 5%, the treatment temperature was 55°C, and the treatment time was 10 minutes, forming a phosphating film with a thickness of 10μm. The thickness of the epoxy primer spray was 50μm, the curing temperature was 165°C, and the curing time was 35 minutes.

[0130] The flame-retardant high-density sound insulation felt used polyester fiber with a diameter of 13μm as the base material, and the fiber length was 45mm. The polyester fiber was mixed with a phosphate flame retardant with a phosphorus content of 23% at a mass ratio of 4:1, and the primary fiber web was prepared using the air-laying technology. The web-forming speed was 10m / min, and the coefficient of variation of the web weight uniformity was controlled within the range of ±3%. The hot pressing and forming temperature was 220°C, the pressure was 3MPa, and the hot pressing time was 4 minutes. The finished product density was 170kg / m 3 , and the thickness tolerance was controlled within the range of ±0.3mm.

[0131] The fire stone slab was composed of calcium silicate and fiber material, and was cut using a high-precision numerically controlled water jet. The water pressure was set at 400MPa, the cutting speed was 250mm / min, and the cutting accuracy was controlled within the range of ±0.2mm. The edge chamfering treatment used a 45° angle, and the chamfer width was 4mm. The surface was polished with 320-mesh sandpaper, and the surface roughness Ra value was 1.2μm.

[0132] When assembling the door body, the lamination process was adopted. The surfaces of each layer of materials were first cleaned with anhydrous ethanol, and then stacked in sequence according to the design order. The layers were bonded with epoxy structural adhesive, and the thickness of the adhesive layer was controlled at 0.25mm, and the glue coating coverage rate reached 97%. The shear strength of the used epoxy structural adhesive was 28MPa, and the tensile strength was 17MPa. The laminated structure was placed in a hydraulic press for pressing, the pressure was 2MPa, the ambient temperature was controlled at 27±1°C, and the curing time was 36 hours. The pressure uniformity was checked and adjusted every 8 hours.

[0133] The door frame adopted a three-channel rabbet design, and a carbon steel plate with a thickness of 3mm was selected as the base material. The depth of each rabbet was 10mm, the width of the rabbet was 18mm, and the dislocation distance between adjacent rabbets was 6mm. The bending processing angle tolerance was controlled within the range of ±0.3°, and the bending radius was 4.2mm. The flatness error of the rabbet surface processing was 0.08mm / m, and the perpendicularity error was 0.15mm / m.

[0134] Install special sealing rubber strips on the tongue-and-groove surface, and select high-temperature resistant silicone rubber material with a Shore A hardness of 70 degrees. The temperature resistance range is -40 to 280 °C, and the oxygen index is 30%. The cutting length of the sealing rubber strip is 2.5% longer than the length of the installation groove to ensure appropriate pre-tightening force after installation. After cleaning the installation groove, apply silicone adhesive with a shear bond strength of 1.5 MPa. The designed compression rate of the sealing rubber strip after installation is 18%, which can provide sufficient sealing pressure when the door body is closed.

[0135] The door body is equipped with three heavy-duty self-closing hinges, and the load-bearing capacity of a single hinge is 100 kg. A four-point locking device is installed, the distance between the lock points is 350 mm, the length of the lock tongue protruding is 25 mm, and locks with a fire rating of Class A are selected. The adjustment range of the pressure regulator is 50 - 200 N, and it is adjusted to 150 N according to the weight of the door body. The gap between the door leaf and the door frame is precisely adjusted to 2.5 mm, and the parallelism error is controlled within 0.8 mm / m.

[0136] After completion of assembly, a comprehensive performance test was carried out. The results of the acoustic performance test are shown in Table 3:

[0137] Table 3 Test Results of the Acoustic Performance of the Sound Insulation Door

[0138]

[0139]

[0140] Calculated according to the GB / T 19889.3 standard, the weighted sound insulation value Rw + C of this sound insulation door is 42 dB, exceeding the minimum requirement of 40 dB for the studio door body. The results of the fire resistance performance test show that within 90 minutes under standard fire conditions, no through-breaking damage occurred to the door body, and the highest temperature on the back side of the fire was 150 °C, meeting the requirements of the 1.5-hour fire resistance rating. The results of the airtightness test indicate that under a pressure difference of 50 Pa, the air leakage per unit door gap length is 0.9 m 3 / h·m, which is better than the standard requirement of 1.5 m 3 / h·m. After the switch durability test was continuously carried out at a frequency of 8 times per minute for 100,000 times, the changes in the functional indicators of the door body did not exceed 5%, showing excellent service durability.

[0141] By analyzing the sound transmission loss values in each frequency band, it is found that the sound insulation performance of the door body structure is relatively weak in the mid-low frequency region (100 - 500 Hz), while it performs excellently in the mid-high frequency region (1000 - 3150 Hz). This is basically consistent with the theoretical prediction and conforms to the acoustic characteristics of the multi-layer composite structure. As the intermediate layer sound insulation material, the fire slate effectively blocks the propagation of mid-high frequency sound waves through its porous structure and high density characteristics, but the blocking effect on low frequency sound waves is relatively weak.

[0142] To further optimize the low-frequency sound insulation performance, it is possible to consider increasing the thickness of the intermediate layer of fire slate or replacing it with graphene composite board to improve the sound insulation effect in the low-frequency region. In addition, the compression rate of the sealing strip has a significant impact on airtightness and sound insulation performance. Practice shows that a compression rate of 18% is the best choice that takes into account both the sealing effect and service life.

[0143] The traditional design of studio door bodies mainly relies on empirical rules. Usually, a simple double-layer steel plate sandwich structure is adopted, with mineral wool or other sound-absorbing materials filled in the middle, lacking systematic theoretical guidance and optimized design. This method often results in a too thick and heavy door body, low material utilization efficiency, and it is difficult to meet the dual requirements of sound insulation performance and fire resistance performance. In addition, the sealing structure in traditional designs often only uses single or double rabbets, making it difficult to effectively block the propagation of sound waves.

[0144] In contrast, the present invention adopts a systematic acoustic isolation parameter design method. Based on the theory of transmission loss and the acoustic transmission matrix equations, combined with the minimum cut maximum flow algorithm to determine the optimal material combination, it achieves a weighted sound insulation amount of 42 dB under the condition that the total thickness is only 51 mm. This performance level usually requires a door body thickness of more than 70 mm in traditional technologies. At the same time, by adopting a combination of flame-retardant high-density sound insulation felt and fire slate, the sound insulation and fire resistance performances are effectively integrated, meeting the requirement of a fire resistance rating of 1.5 hours. The three-rabbet design and the application of special sealing strips in the present invention form an effective acoustic maze structure, greatly improving the sound insulation performance at the door seam, which is a common weakness of traditional sound insulation doors.

[0145] It should be noted that the detailed explanations of the variables involved in the present invention are shown in Table 4 below.

[0146] Table 4 Variable Explanation Table

[0147]

[0148]

[0149] The above is only the specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention can easily think of changes or substitutions, which should all be covered within the protection scope of the present invention.

Claims

1. A production method of a professional fireproof and sound-insulating door applicable to a studio, characterized in that, It includes the following operation steps: conduct acoustic isolation parameter design, construct a mathematical model of the multi-layer structure based on the sound transmission loss theory, represent each layer structure of the door body as a weighted directed graph, and apply the minimum cut maximum flow algorithm to determine the optimal solution of the material combination; cut high-strength carbon steel plates as the outer layer of the door; prepare flame-retardant high-density sound insulation felts; Process the intermediate layer sound insulation material; assemble the door body using the lamination process; The door frame adopts a three-way rabbet design; install special sealing rubber strips on the rabbet surface; assemble the hardware; Conduct finished product testing, measure the acoustic performance of the door body using the reverberation room method, detect that the fire resistance performance meets the fire resistance rating, and conduct the switch durability test to complete the production process; among them, the acoustic transmission matrix equations are used to replace the finite element model for the structural design and optimization of the sound insulation door, including the material impedance equation, the interface transmission equation, the overall transmission equation, and the acoustic evaluation equation.

2. The production method of the professional fireproof and sound-insulating door applicable to a studio according to claim 1, characterized in that, The acoustic isolation parameter design is based on the sound transmission loss theory to construct a mathematical model of the multi-layer structure, represent each layer structure of the door body as a weighted directed graph, apply the minimum cut maximum flow algorithm to determine the optimal solution of the material combination, and optimize the thickness parameters of each layer of materials to make the overall sound insulation performance meet the studio standard requirements; each layer structure of the door body refers to a multi-layer composite structure composed of high-strength carbon steel plates, flame-retardant high-density sound insulation felts, and intermediate layer sound insulation materials, where the high-strength carbon steel plates are located in the outermost layer, the flame-retardant high-density sound insulation felts are located in the second and fourth layers, and the intermediate layer sound insulation materials are located in the third layer.

3. The production method of the professional fireproof and sound-insulating door applicable to a studio according to claim 2, characterized in that, The sound transmission loss theory specifically refers to the quantitative description of the energy attenuation when sound waves propagate from one medium to another, and calculates the sound energy transfer characteristics in the multi-layer structure through the mass law, resonance effect, and coincidence effect; the weighted directed graph specifically refers to a mathematical model used to represent the sound transmission relationship between material layers, where the nodes represent different material layers and the edge weights represent the sound energy transfer efficiency; the minimum cut maximum flow algorithm specifically refers to a graph theory optimization algorithm used to solve network flow problems and is used to find the optimal material combination scheme in the sound insulation door design.

4. The production method of the professional fireproof and sound-insulating door applicable to a studio according to claim 3, characterized in that, Cut high-strength carbon steel plates as the outer layer of the door, ensure the dimensional accuracy within ±0.5 mm through numerical control cutting, and then conduct surface treatment, including rust removal, phosphating treatment, and primer spraying.

5. The production method of the professional fireproof and sound-insulating door applicable to a studio according to claim 4, characterized in that, Prepare the flame-retardant high-density sound insulation felt by mixing polyester fiber and flame retardant in a mass ratio of 4:1 and then hot pressing and forming, controlling the finished product density at 150 to 200 kg per cubic meter and precisely controlling the thickness.

6. The production method of the professional fireproof and sound-insulating door applicable to a studio according to claim 5, characterized in that, Process the intermediate layer sound insulation material, cut the fire slate or graphene composite board to the designed size according to the calculated parameters, and chamfer the edges to ensure tight combination with the door frame; the fire slate specifically refers to a high-density fireproof board composed of calcium silicate and fiber materials, with excellent sound insulation characteristics and fire resistance performance; the graphene composite board specifically refers to a new composite material formed by mixing graphene materials and polymer matrices, with the characteristics of light weight, high sound insulation performance, and high fire resistance rating.

7. The production method of the professional fireproof and sound-insulating door applicable to a studio according to claim 6, characterized in that, The door body is assembled by using a lamination process, with a high-strength carbon steel plate, a flame-retardant high-density sound insulation felt, an intermediate layer sound insulation material, a flame-retardant high-density sound insulation felt, and a high-strength carbon steel plate stacked in sequence, and bonded with an epoxy structural adhesive, and pressed for 24 to 48 hours in an environment with a constant temperature of 25 to 30 degrees Celsius.

8. The production method of the professional fireproof and sound-insulating door applicable to a studio according to claim 7, characterized in that, The door frame adopts a three-way rabbet design and is precisely machined using numerical control equipment. The depth of the rabbet is designed to be 8 to 12 millimeters, and the rabbet surface is completely perpendicular to ensure the sealing effect; the rabbet specifically refers to the concave-convex structure designed on the contact surface between the door leaf and the door frame, forming a labyrinth acoustic barrier to block the direct propagation path of sound waves; a special sealing strip is installed on the rabbet surface, made of high-temperature resistant silicone rubber material, and the compression ratio is designed within the range of 15% to 20% to ensure airtight closure when the door body is closed.

9. The production method of the professional fireproof and sound-insulating door applicable to a studio according to claim 8, characterized in that, The assembled hardware includes heavy-duty self-closing hinges, a multi-point locking device, and a pressure regulator, and the gap between the door leaf and the door frame is adjusted to 2 to 3 millimeters.

10. The production method of the professional fireproof and sound-insulating door applicable to a studio according to claim 9, characterized in that, The material impedance equation is used to calculate the acoustic characteristic parameters of each layer of material. The inputs include material density, Young's modulus, Poisson's ratio, material thickness, and internal loss factor, and the outputs are the material characteristic impedance value and the wave number; the interface transmission equation is used to calculate the propagation characteristics of sound waves at the interface between two materials. The inputs include the incident angle, incident energy, characteristic impedances of the front and rear materials, interface bonding stiffness, and interface thickness, and the outputs are the reflection coefficient and the transmission coefficient; the overall transmission equation is used to integrate the acoustic transmission behavior of a multi-layer structure. The inputs include the transmission matrices of each layer of material, the interface transmission matrix between layers, the total thickness of the structure, and the boundary conditions, and the output is the total transmission matrix of the system; the acoustic evaluation equation is used to quantitatively calculate the sound insulation performance index. The inputs include the total transmission matrix of the system, the standard frequency range, the reference sound pressure level, and the environmental correction factor, and the outputs are the sound transmission loss value and the weighted sound insulation amount Rw + C value; the standard frequency range refers to the frequency interval for evaluating the sound insulation performance, which is 16 one-third octave bands from 100 Hz to 3150 Hz specified in the GB / T 19889.3 standard.

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