A multi-layer composite sound insulation cotton for drain pipes

Abstract

This invention discloses a multi-layer composite sound insulation cotton for drain pipes. It comprises, from the outside in, a release paper layer, a first butyl rubber layer, an IXPE foam layer, a second butyl vibration damping layer, and a non-woven protective layer, stacked sequentially. The first butyl rubber layer is made of modified butyl rubber; the IXPE foam layer is made of cross-linked polyethylene foam with an independent closed-cell structure; and the second butyl vibration damping layer is made of high-damping butyl rubber. The sound insulation cotton of this invention achieves low-temperature continuous bonding and initial vibration damping and waterproofing through the first butyl rubber layer; it achieves sound absorption, sound insulation, and heat preservation through the IXPE foam layer; it forms a constrained damping structure with the second butyl vibration damping layer, the first butyl rubber layer, and the IXPE foam layer to suppress pipe vibration and block sound bridge transmission; and it forms a double waterproof structure with the non-woven protective layer and the first butyl rubber layer to prevent external water vapor penetration. It integrates multiple functions such as bonding, vibration damping, sound absorption, sound insulation, heat preservation, waterproofing, and protection.

Description

Technical Field

[0001] This invention relates to the field of sound insulation and noise reduction technology for building pipes, and more specifically to a multi-layer composite sound insulation cotton for drain pipes. Background Technology

[0002] During interior decoration and daily use, noise from drainage pipes due to water flow impact and pipe vibration has become one of the main noise sources affecting indoor living comfort. This is especially true in high-rise buildings, where drainage pipes run through floors, resulting in significant water drop and high flow velocity, making pipe noise a particularly prominent issue. As people's demands for living environment quality continue to rise, sound insulation and noise reduction of drainage pipes has become an important aspect of interior decoration.

[0003] Currently, the existing sound insulation materials and technical solutions for drain pipes on the market mainly fall into the following categories: (1) Single foam wrapping solution. This method uses a single sound-absorbing material such as rubber-plastic sponge, glass wool, or polyurethane sponge to wrap the pipe, relying on the porous structure of the material itself to absorb some sound wave energy. This solution only achieves basic sound absorption, providing some absorption for mid-to-high frequency noise, but it cannot effectively suppress the vibration of the pipe caused by water flow impact, and is basically ineffective against low-frequency vibration noise. Furthermore, the rigid contact between the pipe and the wrapping material still forms a sound bridge, allowing vibration energy to continue to be transmitted to the wall through the sound bridge, significantly reducing the sound insulation effect.

[0004] (2) Simple Adhesive Layer Composite Solution. Some products use a simple bonding method between the adhesive layer and the sound-absorbing layer, where the sound insulation material is adhered to the outer wall of the pipe during construction. However, these products generally suffer from poor adhesive bonding stability, which is significantly affected by ambient temperature. In low-temperature environments during winter, the bonding strength of ordinary pressure-sensitive adhesives or hot melt adhesives drops sharply, easily leading to hardening of the adhesive layer and loss of adhesion, resulting in delamination and detachment of the sound insulation material. In addition, the adhesive layer of these products usually lacks waterproofing or has weak waterproofing performance, and the adhesion further weakens after long-term use due to aging and moisture absorption.

[0005] (3) Sound insulation felt or damping sheet wrapping scheme. High-density materials such as asphalt-based damping sheets and rubber sound insulation felt are used to wrap the pipes, relying on the material's own mass effect and damping characteristics to suppress vibration. This type of scheme is cumbersome to construct, requiring on-site cutting, heating and softening, and splicing piece by piece, resulting in low construction efficiency. Moreover, asphalt-based materials have odor problems and poor environmental performance, limiting their use indoors. At the same time, these materials usually do not have sound absorption functions and are insufficient in absorbing mid-to-high frequency noise.

[0006] (4) Pipe enclosure solution. The pipe shaft is enclosed by brick or plywood and filled with sound-absorbing cotton. This solution occupies a large space, has a long construction period, and is costly. It is not suitable for renovation of existing buildings that have already been decorated. Summary of the Invention

[0007] In view of this, the present invention provides a multi-layer composite sound insulation cotton for drain pipes that solves the problems mentioned in the background art.

[0008] To achieve the above objectives, the present invention provides the following technical solution, comprising a release paper layer, a first butyl rubber layer, an IXPE foam layer, a second butyl shock-absorbing rubber layer, and a non-woven protective layer, which are stacked and compounded sequentially from the outside to the inside.

[0009] Preferably, in the above-mentioned multi-layer composite drain pipe sound insulation cotton, the first butyl rubber layer is made of modified butyl rubber material, and the first butyl rubber layer has the functions of low-temperature continuous bonding, vibration damping, sound insulation and waterproofing.

[0010] Preferably, in the above-mentioned multi-layer composite drain pipe sound insulation cotton, the bonding strength of the first butyl rubber layer is ≥0.3MPa in an environment of -10℃.

[0011] Preferably, in the above-mentioned multi-layer composite drain pipe sound insulation cotton, the IXPE foam layer is made of cross-linked polyethylene foam material with an independent closed-cell structure inside.

[0012] Preferably, in the above-mentioned multi-layer composite drainage pipe sound insulation cotton, the sound absorption coefficient of the IXPE foam layer is ≥0.4.

[0013] Preferably, in the above-mentioned multi-layer composite drain pipe sound insulation cotton, the second butyl vibration damping layer is made of high-damping butyl rubber.

[0014] Preferably, in the above-mentioned multi-layer composite drainage pipe sound insulation cotton, the damping loss factor of the second butyl vibration damping adhesive layer is ≥0.6.

[0015] Preferably, in the above-mentioned multi-layer composite drainage pipe sound insulation cotton, the non-woven protective layer is a high-density waterproof non-woven fabric.

[0016] Preferably, in the above-mentioned multi-layer composite drain pipe sound insulation cotton, the insulating paper layer is release paper.

[0017] Preferably, in the above-mentioned multi-layer composite drain pipe sound insulation cotton, each layer of material is integrally composited through a hot pressing process.

[0018] As can be seen from the above technical solution, compared with the prior art, the present invention discloses a multi-layer composite drainage pipe sound insulation cotton, which is made by setting an isolation paper layer, a first butyl rubber layer, an IXPE foam layer, a second butyl vibration damping layer and a non-woven protective layer, and stacking each layer in sequence. The first butyl rubber layer is made of modified butyl rubber with a thickness of 1mm, the IXPE foam layer is made of cross-linked polyethylene foam with a thickness of 4mm, the second butyl vibration damping layer is made of high damping butyl rubber with a thickness of 2mm, and the non-woven protective layer is made of waterproof non-woven fabric with a thickness of 0.1mm. Each layer is integrally composited by hot pressing process. The aforementioned structure enables the first butyl rubber layer to provide low-temperature continuous adhesion and initial vibration damping and waterproofing, ensuring a firm bond between the sound insulation cotton and the pipe wall in low-temperature environments. The IXPE foam layer utilizes its independent closed-cell structure to achieve sound absorption, sound insulation, and heat insulation functions, while preventing the material from absorbing moisture. The second butyl vibration damping layer, together with the first butyl rubber layer and the IXPE foam layer, forms a restraint damping structure, effectively suppressing pipe vibration, blocking sound bridge transmission, and reducing low-frequency noise. The non-woven protective layer, in conjunction with the first butyl rubber layer, forms a double waterproof structure, preventing external moisture penetration, protecting the internal materials from moisture and mold, and extending the product's service life. The release paper layer can be directly pasted after peeling during construction, making construction convenient. This sound insulation cotton integrates multiple functions such as adhesion, vibration damping, sound absorption, sound insulation, heat insulation, waterproofing, and protection. The synergistic effect of each layer makes it suitable for sound insulation and noise reduction treatment of drainage pipes in different temperature and humid environments. Detailed Implementation

[0019] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0020] Example 1 This embodiment provides a multi-layer composite sound insulation cotton for drain pipes, which consists of a layer of insulating paper, a first butyl rubber layer, an IXPE foam layer, a second butyl vibration damping layer, and a non-woven protective layer, stacked sequentially from the outside to the inside.

[0021] The release paper layer uses double-sided coated release paper with a basis weight of 60-80 g / m² and a release force of 0.1-0.3 N / 25 mm. The release paper layer adheres to and protects the outer surface of the first butyl rubber layer, preventing it from becoming contaminated with dust, impurities, or accidentally sticking during transportation and storage. It can be easily peeled off during construction without leaving any adhesive residue.

[0022] The first butyl rubber layer has a thickness of 1 mm and is made of environmentally friendly modified butyl rubber. In this embodiment, the first butyl rubber layer is prepared from the following raw materials: 40-50 parts by weight of butyl rubber, 20-30 parts by weight of polyisobutylene, 10-15 parts by weight of tackifying resin, 10-20 parts by weight of filler, 1-3 parts by weight of antioxidant, and 3-5 parts by weight of softener. The above raw materials are internally mixed and extruded to form a sheet-like rubber layer with a thickness of 1 mm. This first butyl rubber layer has low-temperature continuous bonding performance, maintaining stable adhesion within an ambient temperature range of -10℃ to 50℃, with a bonding strength ≥0.3MPa (tested according to GB / T 2792 standard). Simultaneously, the first butyl rubber layer itself has vibration damping, sound insulation, and waterproofing functions. During construction, after peeling off the release paper layer, the sound insulation cotton can be firmly adhered to the outer wall of the drain pipe through the first butyl rubber layer without the need for additional adhesive. The first butyl rubber layer, as the first functional layer closely attached to the pipe, can initially absorb and attenuate the vibration energy of the pipe and prevent condensate from the outer wall of the pipe from penetrating into the internal materials.

[0023] The IXPE foam layer is 4mm thick and made of cross-linked polyethylene (IXPE) foam material with an independent closed-cell structure. In this embodiment, the density of the IXPE foam layer is 25-35kg / m³, the sound absorption coefficient is ≥0.45 (tested according to GB / T 18696.2 standard, frequency range 500-2000Hz), and the thermal conductivity is ≤0.045W / (m·K). The IXPE foam layer is prepared by electron irradiation cross-linking foaming process, in which polyethylene resin, foaming agent, and cross-linking agent are mixed and extruded, cross-linked by electron irradiation, and then heated to foam, resulting in a foam sheet with a uniform independent closed-cell structure. As the core sound-absorbing and sound-insulating functional layer of the sound insulation cotton, this IXPE foam layer can efficiently absorb the mid-to-high frequency noise generated by water flow in pipes. At the same time, its closed-cell structure gives the material the characteristics of not absorbing water and moisture, and combined with its low thermal conductivity, it can also play a role in pipe insulation and preventing condensation on the outer wall.

[0024] The second butyl damping layer is 2mm thick and made of high-damping butyl rubber. In this embodiment, the damping loss factor of the second butyl damping layer is ≥0.6 (tested according to GB / T 18258 standard), and it is prepared by mixing and extrusion molding of butyl rubber, damping filler, tackifying resin and other raw materials. Compared with the first butyl rubber layer, the second butyl damping layer has higher damping characteristics and is also thicker, playing a core role in vibration damping, noise reduction and sound insulation. The second butyl damping layer, together with the first butyl rubber layer and the intermediate IXPE foam layer, forms a constrained damping structure. When the pipeline vibrates due to water flow impact, the first butyl rubber layer, which is close to the pipe wall, vibrates with the pipeline. The vibration energy is transmitted to the second butyl damping layer through the shear deformation of the IXPE foam layer. The two layers of high-damping butyl rubber material efficiently convert the vibration energy into heat dissipation, significantly suppressing pipeline vibration and sound bridge transmission, and significantly improving the overall sound insulation and vibration damping performance.

[0025] The nonwoven protective layer is 0.1mm thick and uses high-density waterproof nonwoven fabric. In this embodiment, the nonwoven fabric is polypropylene (PP) spunbond nonwoven fabric with a basis weight of 15-25g / m², a tensile strength ≥50N / 5cm (tested according to GB / T 3923.1 standard), and a hydrostatic pressure resistance ≥1.5kPa. The nonwoven protective layer is tightly bonded to the outside of the second butyl damping adhesive layer (the side away from the pipe). On the one hand, it provides aesthetic protection, making the product surface smooth and beautiful; on the other hand, it provides waterproof protection. Together with the first butyl adhesive layer, it forms a double waterproof structure, effectively isolating moisture from humid environments such as bathrooms and kitchens, protecting the internal IXPE foam layer and adhesive layer from moisture and mildew, and extending the product's service life.

[0026] In this embodiment, the above-mentioned materials are integrally composited using a hot-pressing process. The specific preparation steps are as follows: Place the IXPE foam layer in the middle layer position; The second butyl damping adhesive layer is hot-pressed onto one side of the IXPE foam layer at a temperature of 100-120℃, a pressure of 0.3-0.5MPa, and a pressing time of 15-30 seconds. The first butyl rubber layer is hot-pressed onto the other side of the IXPE foam layer at a temperature of 80-100℃, a pressure of 0.3-0.5MPa, and a pressing time of 15-30 seconds. The non-woven protective layer is hot-pressed onto the outer surface of the second butyl damping adhesive layer. The hot-pressing temperature is 80-100℃, the pressure is 0.2-0.4MPa, and the pressing time is 10-20 seconds. The release paper layer is adhered to the outer surface of the first butyl rubber layer; Cut to the required width and length, then roll up and package.

[0027] The multi-layer composite drain pipe sound insulation cotton prepared by the above process has each layer tightly bonded together without gaps or delamination, forming an integrated composite structure.

[0028] The sound insulation cotton prepared in this embodiment was adhered to the outer wall of a 110mm PVC drain pipe, and performance tests were conducted. The sound insulation performance test was performed according to the GB / T 19889 series standards, simulating the noise conditions of water flow in a drainage pipe. The test results showed that the drainage noise of the pipe was reduced by 22dB(A). Low-temperature bonding performance test: The PVC pipe with the sound insulation cotton adhered was placed in an environment of -10℃ for 30 days, and no peeling, delamination, or curling was observed. Moisture resistance test: The PVC pipe with the sound insulation cotton adhered was placed in a constant temperature and humidity chamber at 40℃ and 95% relative humidity for 6 months. After removal and inspection, the internal IXPE foam layer showed no moisture absorption or mold growth. The sound insulation performance test showed a noise reduction value of 21.5dB(A), with an attenuation of less than 3%, and a bonding strength retention rate of ≥90%.

[0029] Example 2 The difference between this embodiment and Embodiment 1 is that the thickness of the IXPE foam layer is adjusted to 3mm, while the structure and thickness of other layers are the same as in Embodiment 1. This embodiment is suitable for scenarios where the installation space between the pipe and the wall is limited. Testing showed that the pipe drainage noise was reduced by 18dB(A).

[0030] Example 3 The difference between this embodiment and Embodiment 1 is that the thickness of the second butyl damping adhesive layer is adjusted to 1.5mm, and the damping loss factor is ≥0.55. The structure and thickness of other layers are the same as in Embodiment 1. This embodiment is suitable for applications with higher cost control requirements. Testing showed a 19dB(A) reduction in pipe drainage noise.

[0031] Example 4 The difference between this embodiment and Embodiment 1 is that the thickness of the first butyl rubber layer is 0.8 mm, and the thickness of the second butyl damping rubber layer is 2.5 mm. The structure and thickness of other layers are the same as in Embodiment 1. Testing showed that the pipe drainage noise was reduced by 23 dB(A).

[0032] Example 5 The difference between this embodiment and Embodiment 1 is that the nonwoven protective layer uses polyester (PET) spunbond nonwoven fabric with a basis weight of 20-30 g / m². Other structures, processes, and performance parameters are basically the same as in Embodiment 1.

[0033] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since it corresponds to the method disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to the method section.

[0034] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A multi-layer composite sound insulation cotton for drain pipes, characterized in that, It includes a release paper layer, a first butyl adhesive layer, an IXPE foam layer, a second butyl shock-absorbing adhesive layer, and a non-woven protective layer, which are stacked sequentially from the outside to the inside.

2. The multi-layer composite drain pipe sound insulation cotton according to claim 1, characterized in that, The first butyl rubber layer is made of modified butyl rubber and has the functions of low-temperature continuous bonding, shock absorption, damping and sound insulation, and waterproofing.

3. The multi-layer composite drain pipe sound insulation cotton according to claim 2, characterized in that, The first butyl rubber layer has an adhesive strength of ≥0.3MPa at -10℃.

4. The multi-layer composite drain pipe sound insulation cotton according to claim 1, characterized in that, The IXPE foam layer is made of cross-linked polyethylene foam material with an independent closed-cell structure inside.

5. The multi-layer composite drain pipe sound insulation cotton according to claim 4, characterized in that, The sound absorption coefficient of the IXPE foam layer is ≥0.

4.

6. The multi-layer composite drain pipe sound insulation cotton according to claim 1, characterized in that, The second butyl damping layer is made of high-damping butyl rubber.

7. The multi-layer composite drain pipe sound insulation cotton according to claim 6, characterized in that, The damping loss factor of the second butyl damping adhesive layer is ≥0.

6.

8. The multi-layer composite drain pipe sound insulation cotton according to claim 1, characterized in that, The nonwoven protective layer is a high-density waterproof nonwoven fabric.

9. The multi-layer composite drain pipe sound insulation cotton according to claim 1, characterized in that, The release paper layer is a release liner.

10. The multi-layer composite drainage pipe sound insulation cotton according to any one of claims 1 to 9, characterized in that, The materials of each layer are integrally composited through a hot pressing process.