Gypsum-based sound insulation and heat preservation floor system with geothermal function and construction method thereof

Abstract

A gypsum-based sound insulation and heat preservation floor system with geothermal function and a construction method thereof belong to the technical field of building materials. The floor system comprises, from bottom to top, a structural layer, a sound insulation and heat preservation layer composed of foamed gypsum-based composite material, a heat insulation layer composed of heat insulation material, a heating layer and a leveling layer composed of moisture-proof and mildew-proof gypsum self-leveling mortar. The sound insulation and heat preservation layer, the heat insulation layer and the leveling layer all adopt gypsum-based homogeneous material with micro-expansion effect, which provides a basis for firm bonding of upper and lower layers. On this basis, the configuration of each component in the gypsum-based composite material in the sound insulation and heat preservation layer, the configuration of each component in the heat insulation material in the heat insulation layer and the configuration of each component in the moisture-proof and mildew-proof gypsum self-leveling mortar in the leveling layer make the sound insulation and heat preservation layer, the heat insulation layer and the leveling layer firmly bonded and not displace. Under the formula system of the present application, the gypsum micro-expansion effect makes the floor system not crack, solving the problem of hollowing and cracking of the existing floor.

Description

Technical Field

[0001] This invention relates to a gypsum-based sound insulation and heat-insulating floor slab system with geothermal function and its construction method, belonging to the field of building materials technology. Background Technology

[0002] Since the 20th century, with the continuous development of the world economy and people's pursuit of a high standard of living, energy consumption has been growing at an increasingly rapid pace. In my country, building energy consumption accounts for about one-third of the total social energy consumption, with heating and air conditioning energy consumption being the largest component, accounting for more than 50% of total building energy consumption. This is a crucial part of my country's energy consumption, and solving the building energy consumption problem is a key issue for the development of my country's construction industry. Currently, underfloor heating is widely used due to its advantages such as high comfort, long service life, and increased indoor usable area. However, existing underfloor heating systems have disadvantages such as slow heat transfer speed, low efficiency, and easy heat loss downwards through the floor slab, resulting in energy waste. In addition, most of the insulation materials in existing underfloor heating systems are organic materials, which have poor durability, are prone to aging, and experience a significant increase in heat loss over time, leading to substantial energy consumption.

[0003] With the improvement of people's living standards, higher requirements are placed on the health performance, environmental performance, and sound insulation performance of residential buildings. Among these, the indoor acoustic environment is most closely related to people's quality of life. The main factors affecting the indoor acoustic environment are the impact sound of floor slabs between floors and airborne sound transmission, as well as airborne sound transmission through partition walls within the same floor. Since the attenuation of solid sound propagation in building structures is very small, impact sound from floor slabs has the greatest impact. Most existing buildings use ordinary concrete floor slabs, which are generally 120mm thick. Their impact sound insulation performance is far higher than the 75dB required by the national standard GB50118-2005, failing to meet the requirements for impact sound insulation. In addition, the heat transfer coefficient of ordinary concrete floor slabs is almost twice that of the national standard GB55015 and the local standard DBJ51 / 143, resulting in poor thermal insulation performance. This fails to meet the building energy conservation requirements, seriously affecting building quality and leading to huge social energy consumption.

[0004] Currently, to address the problems of sound insulation and thermal insulation in floor slabs, the following three measures are commonly used: laying an elastic surface layer, adding a soundproof ceiling, and installing an organic floating floor slab. Laying an elastic surface layer can effectively reduce impact noise from the floor slab, but its effect on airborne sound insulation is limited. Adding a soundproof ceiling can improve sound insulation, but noise generated on the floor slab surface can still propagate along the solid structure of the building through the surrounding walls, and its sound insulation of impact noise still cannot meet the requirements of general residential buildings. Floating floor slab systems, which consist of the original floor slab + vibration damping pad + reinforced concrete layer, are widely used in building construction, especially organic floating floor slab systems, which, from bottom to top, consist of a floor slab structural layer, a sound insulation and vibration damping layer, a leveling floating layer, and a floor decoration layer.

[0005] However, a significant problem facing organic floating floor systems is that the most widely used sound insulation materials in current sound insulation and vibration damping layers are organic sound insulation materials such as polyethylene foam, polyurethane, and polyester fiber thermal insulation composites. These organic sound insulation materials are chemically unstable, releasing toxic and harmful substances during use, have poor flame retardant properties, easily cause environmental pollution, have high water vapor permeability, are prone to decomposition and mold growth, and have weak weather resistance. Furthermore, the leveling floating layer in the aforementioned organic floating floor system requires a 40mm thick fine aggregate concrete layer reinforced with steel mesh, which must be kept moist and cured, typically taking about 7 days. The leveling floating layer has poor adhesion to adjacent layers, making it prone to delamination, flammability, and cracking. Cracks can cause displacement of the underlying layers, resulting in gaps that affect heat insulation and reflection effects. Summary of the Invention

[0006] In view of this, in order to solve the problems of poor thermal insulation, poor adhesion, easy delamination and cracking, and long construction period of existing floor slab systems with geothermal function, the purpose of this invention is to provide a gypsum-based sound insulation and heat-insulating floor slab system with geothermal function and its construction method. The floor slab system has a firm bond between the upper and lower layers, does not produce displacement, and has good sound insulation and heat insulation performance; the heat insulation layer can efficiently reflect heat and reduce heat loss downward, thus having a good heat insulation effect; in the construction method of the floor slab system, after the gypsum self-leveling layer is poured, people can walk on it and carry out the next process 4 hours later.

[0007] To achieve the objectives of this invention, the following technical solutions are provided.

[0008] A gypsum-based sound-insulating and heat-insulating floor system with geothermal function, the floor system comprising, from bottom to top, a structural layer, a sound-insulating and heat-insulating layer, a heat insulation layer, a heating layer, and a leveling layer; the floor system also includes a floor decoration layer disposed on the leveling layer;

[0009] The sound insulation and heat preservation layer is composed of foamed gypsum-based composite material, the heat insulation layer is composed of heat insulation material, and the leveling layer is composed of moisture-proof and mildew-proof gypsum self-leveling mortar.

[0010] The foamed gypsum-based composite material is composed of the following components in parts by weight: 60-85 parts of β-type building gypsum or α-type high-strength gypsum, 0.06-0.12 parts of retarding water-reducing agent, 30-50 parts of water, 3 parts of waterproofing agent (greater than 0 and less than or equal to 3), 1-3 parts of composite foaming agent, and 5-15 parts of lightweight aggregate. The impact sound insulation of the sound insulation layer is ≤60dB, and the thermal conductivity is ≤0.12W / (m·K). The thickness of the sound insulation layer is set according to application requirements, and shall not exceed 50mm.

[0011] The lightweight aggregate is one or more of the following: 80-100 mesh open-cell vitrified microspheres, 60-80 mesh open-cell perlite, 200-300 mesh aerated concrete, and 10-40 mesh ceramic ceramsite.

[0012] Preferably, the composite foaming agent is composed of the following components in parts by weight: foam stabilizer: 0.1 to 0.5 parts, physical foaming agent: 8 to 10 parts, sodium sulfate: 0.1 to 0.3 parts; the composite foaming agent composed of foam stabilizer, physical foaming agent and sodium sulfate, when used in conjunction with gypsum, enables the foamed gypsum-based composite material to have a collapse loss of ≤2 mm in 1 hour, an effective flow time of 25 to 35 minutes, a final setting time of 40 to 50 minutes, a compressive strength of 3 MPa to 6 MPa, and a water absorption rate of ≤3%.

[0013] The open-cell vitrified microspheres, open-cell perlite, and aerated concrete in lightweight aggregates all have the characteristics of low bulk density, low water absorption, and low thermal conductivity; preferably, the density of the open-cell vitrified microspheres is 80 kg / m³. 3 ~120kg / m 3 The density of the porous perlite is 60 kg / m³. 3 ~80kg / m 3 The density of the aerated concrete is 32 kg / m³. 3 The density difference gives the foamed gypsum-based composite material good thermal insulation properties.

[0014] Preferably, the lightweight aggregate is composed of the following components in parts by weight: 1 to 5 parts of 100-mesh open-cell vitrified microspheres and 5 to 10 parts of 30-mesh ceramic ceramsite; and the ceramic ceramsite has a porosity ≥18%, an adsorption rate ≥20%, a compressive strength ≥1MPa, and a sphericity ≥0.95.

[0015] More preferably, the ceramic granules are silver ion-containing graphene ceramic granules, wherein silver ions and graphene are uniformly distributed on the surface and inside of the ceramic granules; the particle size of the silver ion-containing graphene ceramic granules is 3mm to 6mm, the porosity is ≥18%, the adsorption rate is ≥20%, the compressive strength is ≥1MPa, and the sphericity is ≥0.95; in the silver ion-containing graphene ceramic granules, silver ions and graphene synergistically inhibit bacteria, with an antibacterial rate of over 99%; the ceramic granules have a porous structure with high porosity and good sound absorption performance, while the uniform distribution of silver ions on the surface and inside of the spheres improves the antibacterial efficiency and extends the service life.

[0016] The thermal insulation material is composed of the following components in parts by weight: gypsum powder: 30-50 parts, hollow glass microspheres: 10-20 parts, retarding water-reducing agent: 3-5 parts, latex: 30-40 parts, titanium dioxide: 1-5 parts, and thermal insulation material: 5-8 parts; wherein the solid content of the latex is ≥35%. The thermal conductivity of the thermal insulation layer is ≤0.05W / (m·K), and the density is ≤300kg / m³. 3 The elongation rate is ≥5%, and the water absorption rate is ≤1%. The thickness of the insulation layer is set according to application requirements, and shall not exceed 3mm.

[0017] The combination of components in the insulation material efficiently reflects heat and reduces downward heat loss. For example, the inclusion of hollow glass microspheres, titanium dioxide, and latex effectively reflects heat. The latex and insulation materials further reduce downward heat loss. Therefore, when this insulation material is applied to the floor system, the indoor temperature can be 4-6°C lower than that of floor systems containing other insulation materials, resulting in energy savings of 10%-20% and an increase in thermal efficiency of 30%-50%. Furthermore, gypsum, being a brittle material, does not crack after the addition of latex, maintaining the integrity of the insulation layer.

[0018] Preferably, the hot water pipes in the heating layer are made of plastic pipes, heat-resistant polyethylene (PE-RT) pipes, or cross-linked aluminum-plastic composite (XPAP) pipes, and are arranged in a double or single pipeline configuration, with the spacing between coils controlled between 100mm and 300mm.

[0019] The moisture-proof and mildew-proof gypsum self-leveling mortar is composed of the following components in parts by weight: phosphogypsum or desulfurized gypsum: 100-120 parts, water: 35-50 parts, retarding water-reducing agent: 0.26-1.12 parts, waterproofing agent: 0.2-0.8 parts, and mildew inhibitor: 0.2-0.5 parts. The moisture-proof and mildew-proof gypsum self-leveling mortar composed of the above components has the following characteristics: 30-minute flowability loss ≤3mm, water absorption rate ≤1%, shrinkage rate ≤0.01%, mildew resistance rating of 0, and fire resistance rating of A. The thickness of the leveling layer is set according to application requirements, with a maximum of 30mm.

[0020] Preferably, the retarding water-reducing agent used in the foamed gypsum-based composite material, thermal insulation material, and moisture-proof and mildew-proof gypsum self-leveling mortar is the retarding water-reducing agent described in the Chinese patent application document "A Retarding Water-Reducing Agent for Phosphate Building Gypsum and Its Preparation Method" with patent publication number CN110482901A. This retarding water-reducing agent is composed of the following components in parts by weight: 90-100 parts of polycarboxylate-based mother liquor or melamine-based mother liquor, 9-20 parts of borax, 0.2-1.0 parts of retarder, 0-1.5 parts of cellulose ether, 0.1-0.2 parts of suspension stabilizer, 0.1-1 parts of defoamer, and 90-100 parts of water.

[0021] Preferably, the waterproofing agent used in the foamed gypsum-based composite material and the moisture-proof and mildew-proof gypsum self-leveling mortar is the waterproofing agent described in the Chinese patent application document "A Composite Gypsum Waterproofing Agent and Its Application Method" with patent publication number CN109851275A. This waterproofing agent comprises the following components in parts by weight: 1.5-2.8 parts of sodium alkylsilicate, 2.0-3.9 parts of stearic acid, 15.8-24.2 parts of alum, 11.2-22.4 parts of titanium dioxide, 75.0-100.0 parts of cement, 150.0-200.0 parts of mineral powder, and 0.5-1.0 parts of hydroxyl-terminated modified hyperbranched polymer.

[0022] Preferably, the antifungal agent used in the moisture-proof and mildew-proof gypsum self-leveling mortar is the antifungal agent described in Chinese patent application document CN111847975A, entitled "Preparation and Application Method of a Waterproof Gypsum Composite Antifungal Agent." This antifungal agent comprises the following components in parts by weight: 3-8 parts inorganic antibacterial component, 3-8 parts chitosan, 3-7 parts sodium methylsilicate, 4-14 parts silicone-acrylic emulsion, 0.2-2 parts pH adjuster, and 0.1-1 parts sodium dodecyl sulfate; the inorganic antibacterial component includes 1-3 parts nano-silver, 1-3 parts borax, and 1-5 parts nano-titanium dioxide. This antifungal agent is a waterproof gypsum composite antifungal agent. It interferes with and inhibits the DNA / RNA synthesis technology of mold by destroying and preventing the formation of cell membranes of mold pathogens in phosphogypsum products, leading to the death of pathogens and achieving the inhibitory effect on mold, yeast, and algae.

[0023] The floor system also includes a floor decoration layer set above the leveling layer; the flooring in the floor decoration layer can be determined according to application requirements, such as wood flooring, stone, ceramic tiles, mosaic tiles or composite flooring; when stone, ceramic tiles or mosaic tiles are used as flooring, an adhesive layer is laid underneath; when wood flooring or composite flooring is used as flooring, a moisture-proof layer is laid underneath.

[0024] Preferably, when the floor is stone tile, ceramic tile or mosaic tile, the bonding layer is selected from polymer cement-based bonding mortar, gypsum bonding mortar or moisture-proof and mildew-proof gypsum bonding mortar, more preferably moisture-proof and mildew-proof gypsum bonding mortar, the thickness of which should be 4 to 6 mm, and the mildew resistance level should be 0, the pull-out bond strength ≥1.5 MPa, and the fire resistance level should be A.

[0025] When the flooring is wood flooring or composite flooring, the moisture-proof layer shall be made of pearl cotton (EPE), ethylene-vinyl acetate copolymer (EVA), electronically cross-linked polyethylene foam (IXPE), plasticizer-free polyvinyl chloride (UPVC), aluminum foil mat, or paper mat, and its thickness shall be controlled between 1.5mm and 2.5mm, with a water absorption rate ≤0.5%.

[0026] A construction method for a gypsum-based sound-insulating and heat-insulating floor slab system with geothermal function according to the present invention, the steps of which are as follows:

[0027] (1) Base treatment and elevation level line: Clean the structural layer and determine the thickness of each layer; that is, clean the structural layer in the system, including sweeping away floating dust and debris on the surface of the structural layer; use a laser level to mark the elevation level line on the surrounding walls and determine the thickness of each layer;

[0028] (2) Apply vertical sound insulation strips: Apply vertical sound insulation strips at the corners of the walls and the thresholds, and make sure that the top of the vertical sound insulation strips is level with the bottom of the floor;

[0029] For example, the height of the vertical sound insulation strip should be 1.5mm to 6mm higher than the leveling layer; when the flooring in the floor decoration layer is made of stone tiles, ceramic tiles, or mosaic tiles, and the bonding layer is made of polymer cement-based bonding mortar, gypsum bonding mortar, or moisture-proof and mildew-proof gypsum bonding mortar, the vertical sound insulation strip should be 4mm to 6mm higher than the leveling layer and flush with the top of the bonding layer, that is, the top of the vertical sound insulation strip should be level with the bottom of the floor.

[0030] When the flooring in the ground decoration layer is wood flooring and the moisture-proof layer is made of EPE, EVA, IXPE, UPVC, aluminum film mat or paper mat, the vertical sound insulation strip should be 1.5mm to 2.5mm higher than the leveling layer and flush with the top of the moisture-proof layer, that is, the top of the vertical sound insulation strip is level with the bottom of the floor.

[0031] (3) Preparation of sound insulation and heat preservation layer:

[0032] A sound insulation and heat preservation layer is prepared on the cleaned structural layer using either a wet or dry process, specifically as follows:

[0033] When using a wet process, a foamed gypsum-based composite material slurry is prepared using a foaming and mixing equipment. The mixing time is 3 to 5 minutes, and the slurry is mixed evenly. The fluidity of the slurry is controlled at 120 ± 3 mm. The slurry is then evenly poured onto the cleaned structural layer to form a continuous, seamless sound insulation and heat preservation layer. The next process, namely the preparation of the heat insulation layer, is carried out 0.5 to 1 hour after the sound insulation and heat preservation layer is poured.

[0034] When using a dry process, the prefabricated components of foamed gypsum-based composite material with pre-reserved pipe grooves are prepared in a prefabrication plant. The depth of the pipe grooves is 1 / 2 to 2 / 3 of the diameter of the hot water pipe. The component size is adjusted according to application requirements. The prefabricated components are laid on the structural layer, and the joint width between the prefabricated components is less than 0.5 mm to form a sound insulation and heat preservation layer.

[0035] (4) Prepare a heat insulation layer, a heating layer and a leveling layer on the sound insulation and heat insulation layer.

[0036] For the sound insulation and heat insulation layer prepared by wet process, after the foamed gypsum-based composite material slurry is poured for 0.5h to 1h, the heat insulation material is poured on the sound insulation and heat insulation layer. After 1h to 2h after the pouring is completed, the heat insulation layer is obtained. Then, hot water pipes are laid to form a heating layer. Finally, moisture-proof and mildew-proof gypsum self-leveling mortar is poured to form a leveling layer.

[0037] For the sound insulation and heat insulation layer prepared by dry process, heat insulation material is applied to the sound insulation and heat insulation layer, and heat insulation material is used to seal the joints of the foamed gypsum-based prefabricated components. The heat insulation layer is obtained 0.5h to 1h after the heat insulation material is applied. Hot water pipes are embedded in the foamed gypsum-based prefabricated components to form a heating layer. Then, moisture-proof and mildew-proof gypsum self-leveling mortar is poured to form a leveling layer.

[0038] (5) The sound insulation and heat insulation layer, the heat insulation layer and the leveling layer are constructed continuously and can be cured naturally. Four hours after the leveling layer is poured, people can walk on it to carry out the next process and lay the floor decoration layer.

[0039] Excluding the floor decoration layer, the construction period up to the completion of the leveling layer is 6 to 8 hours.

[0040] Beneficial effects

[0041] (1) This invention provides a gypsum-based sound-insulating and heat-insulating floor system with geothermal function. The sound-insulating and heat-insulating layer, the heat insulation layer, and the leveling layer in the floor system are all gypsum-based homogeneous materials with a micro-expansion effect, providing a foundation for strong adhesion between the upper and lower layers. Based on gypsum-based homogeneous materials, this invention optimizes the configuration of each component in the gypsum-based composite material of the sound-insulating and heat-insulating layer, the configuration of each component in the heat insulation material of the heat insulation layer, and the configuration of each component in the moisture-proof and mildew-proof gypsum self-leveling mortar of the leveling layer, ensuring a strong bond between the sound-insulating and heat-insulating layer, the heat insulation layer, and the leveling layer, preventing displacement. Under the formulation system of this invention, the micro-expansion effect of gypsum prevents the floor system from cracking, solving the problem of hollow cracking in existing floor systems.

[0042] The heating coils are arranged under the leveling layer, and the entire leveling layer is used as a radiator to ensure that the entire ground is heated evenly. In addition, the heat insulation material described in this invention can efficiently reflect heat in a directional manner and reduce heat loss downward. This invention can achieve a livable indoor design temperature that is 4-6°C lower than other heating methods, with energy savings of up to 20% and thermal efficiency increased by 50%.

[0043] The heat transfer coefficient of the floor system described in this invention is ≤1.2 W / (m²). 2 The heat transfer coefficient of the floor slab is 33% higher than the standard, but less than half that of the traditional floor slab, meeting the requirement of ≤1.8W / (m²) for the heat transfer coefficient of the individual floor slabs as specified in the "Sichuan Provincial Residential Building Energy Conservation Design Standard" DB51-5027. 2 It has excellent heat preservation properties (·K).

[0044] The carbon emissions of the floor system described in this invention are less than 40% of those of the organic sound-insulating floating floor system. The gypsum used in this invention is Class A fire-resistant, so the floor system is also Class A fire-resistant. The leveling layer of the floor system described in this invention is high-strength and durable, and also has moisture-proof and mildew-proof properties, with a mildew-proof rating of 0.

[0045] (2) This invention provides a gypsum-based sound insulation and heat-insulating floor slab system with geothermal function, wherein the density of vitrified microspheres in the lightweight aggregate is 80 kg / m³. 3 ~120kg / m 3 Perlite has a density of 60 kg / m³. 3 ~80kg / m 3 The density of aerated concrete is 32 kg / m³. 3 By utilizing the density difference, the foamed gypsum-based composite material exhibits excellent thermal insulation properties.

[0046] (3) The present invention provides a gypsum-based sound insulation and heat preservation floor system with geothermal function. In the silver ion graphene ceramic granules, silver ions and graphene work together to fight bacteria, with an antibacterial rate of over 99%. The ceramic granules have a porous structure with high porosity and good sound absorption performance. At the same time, silver ions are evenly distributed on the surface and inside of the spheres, which improves the antibacterial efficiency and extends the service life.

[0047] (4) The present invention provides a gypsum-based sound insulation and heat insulation floor system with geothermal function. The flooring in the ground decoration layer can be determined according to the application requirements, such as wood flooring, stone, ceramic tiles, mosaic tiles or composite flooring; when stone, ceramic tiles or mosaic tiles are used as flooring, an adhesive layer is laid on the bottom; when wood flooring or composite flooring is used as flooring, a moisture-proof layer is laid on the bottom.

[0048] (5) This invention provides a construction method for a gypsum-based sound insulation and heat insulation floor system with geothermal function. Based on the performance characteristics of gypsum-based materials, this invention proposes a professional construction method. People can walk on it 4 hours after construction, no curing is required, and the construction period is less than 1 / 10 of that of organic material sound insulation floor systems. In addition, the sound insulation and heat insulation layer, heat insulation layer and leveling layer in the floor system of this invention are all gypsum-based homogeneous materials with micro-expansion effect. At the same time, the continuous construction of different layers using this invention provides a better foundation for the firm bonding of the upper and lower layers. Attached Figure Description

[0049] Figure 1 The results are the anti-mold test results of the floor system described in Comparative Example 2.

[0050] Figure 2 The results are the anti-mold test results of the floor system described in Example 1.

[0051] Figure 3The results are the anti-mold test results of the floor system described in Example 2.

[0052] Figure 4 The results are the anti-mold test results of the floor system described in Example 3.

[0053] Figure 5 The results are the anti-mold test results of the floor system described in Example 4.

[0054] Figure 6 The results are the anti-mold test results of the floor system described in Example 5. Detailed Implementation

[0055] The present invention will be further described below with reference to specific embodiments. Unless otherwise specified, the methods described are conventional methods, and the raw materials described are available from publicly available commercial sources or prepared according to literature.

[0056] Comparative Example 1

[0057] The floor system provided in this comparative example consists of a 120mm thick C30 concrete floor structure layer and a 30mm thick cement mortar leveling layer, from bottom to top.

[0058] Comparative Example 2

[0059] This comparative example provides a floor system comprising, from bottom to top, a 120mm thick C30 concrete as the floor structural layer, a 2mm thick polyurethane material as the sound insulation and vibration damping layer, a single-pipe plastic pipe as the heating layer, a 50mm thick leveling floating layer composed of C25 fine aggregate reinforced with steel mesh, a 1.5mm thick EVA moisture-proof layer with a water absorption rate ≤0.5%, and a 12mm thick wooden floor.

[0060] Example 1

[0061] A gypsum-based sound insulation and heat-insulating floor system with geothermal function, wherein the floor system comprises, from bottom to top, a structural layer, a sound insulation and heat-insulating layer, a heat insulation layer, a heating layer, a leveling layer, and a floor decoration layer.

[0062] The structural layer is composed of 120mm thick C30 concrete; the sound insulation and heat preservation layer is composed of 30mm thick foamed gypsum composite material; the heat insulation layer is composed of 1mm thick heat insulation material; the heating layer is composed of single plastic pipes with a coil spacing controlled at 200mm; the leveling layer is composed of 20mm thick moisture-proof and mildew-proof gypsum self-leveling mortar; the floor decoration layer consists of a 1.5mm thick EVA moisture-proof layer with a water absorption rate ≤0.5%, and a 12mm thick wood flooring, starting from the leveling layer.

[0063] The raw materials of the foamed gypsum-based composite material are composed of the following components in parts by weight: β-type building gypsum: 70 parts, retarding water-reducing agent: 0.08 parts, water: 40 parts, waterproofing agent: 1 part, composite foaming agent: 2 parts, and 30-mesh silver ion-containing graphene ceramic ceramsite: 8 parts.

[0064] The raw materials of the composite foaming agent are composed of the following components in parts by weight: foam stabilizer: 0.2 parts, physical foaming agent: 8 parts, sodium sulfate: 0.12 parts.

[0065] The silver ion-containing graphene ceramic particles have a particle size of 5 mm, a porosity of 20%, an adsorption rate of 21%, a compressive strength of 2 MPa, and a sphericity of 0.96.

[0066] The raw materials of the thermal insulation material are composed of the following components in parts by weight: gypsum powder: 40 parts, hollow glass microspheres: 15 parts, retarding water-reducing agent: 4 parts, latex: 35 parts, rutile titanium dioxide: 2 parts, thermal insulation material: 6 parts; wherein, the solid content of the latex is 40%.

[0067] The raw materials of the moisture-proof and mildew-proof gypsum self-leveling mortar are composed of the following components in parts by weight: desulfurized gypsum: 100 parts, water: 35 parts, retarding water-reducing agent: 0.26 parts, waterproofing agent: 0.35 parts, and mildew inhibitor: 0.2 parts.

[0068] The retarding water-reducing agent used in the foamed gypsum-based composite material, thermal insulation material, and moisture-proof and mildew-proof gypsum self-leveling mortar is the retarding water-reducing agent described in the Chinese patent application document "A Retarding Water-Reducing Agent for Phosphorus Building Gypsum and Its Preparation Method" with patent publication number CN110482901A. The retarding water-reducing agent is composed of the following components in parts by weight: 92 parts polycarboxylate mother liquor, 10 parts borax, 0.5 parts protein retarder, 0.7 parts hydroxypropyl methylcellulose ether, 0.15 parts cellulose nanospheres, 0.8 parts polysiloxane, and 97 parts water.

[0069] The waterproofing agent used in the foamed gypsum-based composite material and the moisture-proof and mildew-proof gypsum self-leveling mortar is the waterproofing agent described in the Chinese patent application document "A Composite Gypsum Waterproofing Agent and Its Application Method" with patent publication number CN109851275A. The waterproofing agent comprises the following components in parts by weight: 2 parts of sodium alkyl silicate, 3 parts of stearic acid, 20 parts of alum, 16 parts of titanium dioxide, 85 parts of silicate cement, 180 parts of S95 mineral powder, and 0.8 parts of hydroxyl-terminated modified hyperbranched polymer; the hydroxyl-terminated modified hyperbranched polymer is a hyperbranched polymer modified with tetradecyl chloride.

[0070] The antifungal agent used in the moisture-proof and mildew-proof gypsum self-leveling mortar is the antifungal agent described in the Chinese patent application document "Preparation and Application Method of a Waterproof Gypsum Composite Antifungal Agent" with patent publication number CN111847975A. The antifungal agent is composed of the following components in parts by weight: 6 parts of inorganic antibacterial component, 6 parts of chitosan, 6 parts of sodium methylsilicate, 10 parts of silicone acrylic emulsion, 1 part of sodium bicarbonate, and 0.5 parts of sodium dodecyl sulfate; each part of the inorganic antibacterial component is composed of 2 parts of nano silver, 2 parts of borax, 3 parts of nano titanium dioxide, and 12 parts of montmorillonite.

[0071] The floor slab system described in this embodiment is constructed using a dry construction method, as follows:

[0072] (1) Base treatment and elevation level line: Clean the structural layer of the system, including sweeping away dust and debris from the surface of the structural layer; use a laser level to mark the elevation level line on the surrounding walls to determine the thickness of each layer;

[0073] (2) Apply vertical sound insulation strips: Apply vertical sound insulation strips at the corners and thresholds of the walls. The height of the vertical sound insulation strips should be 1.5mm higher than the leveling layer and flush with the top of the moisture-proof layer, that is, the top of the vertical sound insulation strips should be flush with the bottom of the floor.

[0074] (3) Casting foamed gypsum-based composite material: Using a dry process, foamed gypsum-based composite material prefabricated components with reserved pipe grooves (the depth of the pipe groove is 1 / 2 of the diameter of the hot water pipe) are prepared by a prefabrication plant. The component size is adjusted according to the application requirements. The prefabricated components are laid on the structural layer. The joint width of the foamed gypsum-based prefabricated components is less than 0.5 mm to form a sound insulation and heat preservation layer.

[0075] (4) Prepare a heat insulation layer, a heating layer and a leveling layer on the sound insulation and heat insulation layer.

[0076] The heat insulation material is applied to the sound insulation and heat preservation layer. At the same time, the heat insulation material is used to seal the joints of the foamed gypsum-based prefabricated components. 0.5 hours after the heat insulation material is applied, hot water pipes are embedded in the foamed gypsum-based prefabricated components. Then, moisture-proof and mildew-proof gypsum self-leveling mortar is poured to prepare the leveling layer.

[0077] (5) The sound insulation and heat insulation layer, the heat insulation layer and the leveling layer are constructed continuously and can be cured naturally. Four hours after the leveling layer is poured, people can walk on it to carry out the next process and lay the floor decoration layer.

[0078] Excluding the floor decoration layer, the construction period up to the completion of the leveling layer is 6 to 8 hours.

[0079] Example 2

[0080] This embodiment of a gypsum-based sound insulation and heat-insulating floor system with geothermal function differs from Embodiment 1 in that the weight of the latex is 40 parts, while the rest are the same as in Embodiment 1.

[0081] Example 3

[0082] This embodiment of a gypsum-based sound insulation and heat-insulating floor system with geothermal function differs from Embodiment 1 in that the heat insulation layer is composed of a 2mm thick heat insulation material, wherein the weight of latex is 40 parts, and the rest are the same as in Embodiment 1.

[0083] Example 4

[0084] This embodiment of a gypsum-based sound and heat-insulating floor system with geothermal function differs from Embodiment 1 in that: the sound and heat insulation layer is composed of a foamed gypsum composite material with a thickness of 40 mm; the heat insulation layer is composed of a heat insulation material with a thickness of 2 mm, wherein the weight of latex is 40 parts, and the rest are the same as in Embodiment 1.

[0085] Example 5

[0086] This embodiment of a gypsum-based sound and heat-insulating floor system with geothermal function differs from Embodiment 1 in that: the sound and heat insulation layer is composed of a 40mm thick foamed gypsum composite material, wherein 10 parts by weight of 30-mesh ceramic ceramsite are contained, and 3 parts by weight of 100-mesh open-cell vitrified microspheres are also contained; the heat insulation layer is composed of a 2mm thick heat insulation material, wherein 40 parts by weight of latex are contained; the rest are the same as in Embodiment 1.

[0087] Test case

[0088] The floor systems provided in Comparative Examples 1-2 and Examples 1-5 were subjected to acoustic performance testing. The weighted normalized impact sound pressure level and the improvement in impact sound pressure level of each floor system were tested through a pilot-scale simulation test of sound source impact. The heat transfer coefficient and carbon emissions of each floor system were calculated using the following formulas. The data of the weighted normalized impact sound pressure level, the improvement in impact sound pressure level, the heat transfer coefficient and the carbon emissions are shown in Table 1.

[0089] The heat transfer coefficient (K) is calculated using the following formula:

[0090] K = 1 / R, where R is the total thermal resistance of the sound-insulating and heat-insulating floor slab.

[0091] Carbon emissions (C JZ The carbon emission calculation is performed according to the carbon emission calculation formula in GB / T51366-2019 "Standard for Calculation of Carbon Emissions in Buildings".

[0092] The mechanical properties and moisture-proof and mildew-proof properties of Comparative Example 2 and Examples 1-5 are shown in Table 2. The antifungal test was conducted according to the standard ASTM G21, "Determination of Antifungal Resistance of Synthetic Polymer Materials." The antifungal resistance level was determined by visually observing the area of ​​fungal growth (Level 0: No fungal growth, extremely strong antifungal properties; Level 1: Fungal growth and spore formation traces, area < 10%, relatively strong antifungal properties; Level 2: Small amount of fungal growth and spore formation, 10% < area < 30%, no antifungal properties; Level 3: Small amount of fungal growth and spore formation, 30% < area < 60%, no antifungal properties; Level 4: Small amount of fungal growth and spore formation, 60% < area < 100%, no antifungal properties). The selected fungal species were: *Aspergillus niger*—ATCC 16404; *Penicillium pineophilum*—ATCC 11797; *Chaetoceros globosum*—ATCC 6205; *Cladosporium brevichorum*—ATCC 9645; *Cladosporium buddingum*—ATCC 15233). Table 1. Weighted normalized impact sound pressure level, impact sound pressure level improvement, heat transfer coefficient, and carbon emissions for Comparative Examples 1-2 and Examples 1-5

[0093]

[0094] Note: The comparison of carbon emission calculation, fire resistance rating, and areal density does not include the structural layer.

[0095] As shown in Table 1, the weighted normalized impact sound pressure levels of Examples 1-5 are all lower than those of Comparative Examples 1-2, and the improvement in impact sound pressure level is greater than that of Comparative Examples 1-2. This indicates that when foamed gypsum-based composite materials are used as sound insulation and heat preservation layers, and polyurethane is used as sound insulation and vibration damping layers for floating floors, the sound insulation effect of foamed gypsum-based composite materials in Examples 1-5 is better than that of polyurethane used as sound insulation and vibration damping layers for floating floors, under the same impact sound source. Moreover, the impact sound insulation effect of Example 5 is the best.

[0096] Comparing the heat transfer coefficients of Examples 1-5 and Comparative Example 2 shows that the thermal performance of the floor systems in Examples 1-5 is improved compared to the floor system in Comparative Example 2, which uses polyurethane as the sound insulation and vibration damping layer. Carbon emission calculations show that the carbon emissions of the floor systems in Examples 1-5 are significantly lower than those in Comparative Example 2, both less than 40% of the emissions of the organic material sound-insulating floating floor system, making them more environmentally friendly.

[0097] Therefore, compared to Comparative Examples 1-2, the floor systems obtained in Examples 1-5 have good sound insulation and a low heat transfer coefficient, resulting in good thermal insulation. Their fire rating is Class A, indicating good fire resistance. Furthermore, the surface density of the floor systems obtained in Examples 1-5 is lower than that of Comparative Example 2, indicating that the floor systems obtained in Examples 1-5 are lighter, thus placing less load on the building and making it safer. Due to their lighter weight, the floor systems also have better thermal insulation properties.

[0098] Table 2 shows the mechanical properties and moisture-proof and mildew-proof properties of Comparative Examples 2 and Examples 1-5.

[0099] Compressive / Flexural Strength / MPa Shrinkage rate / % Anti-mildew properties Water absorption rate / % Comparative Example 2 25.6 / 3.2 0.043 4 15.5 Example 1 26.5 / 7.6 0.004 0 1.0 Example 2 27.1 / 8.3 0.005 0 0.9 Example 3 27.1 / 7.8 0.007 0 0.8 Example 4 26.9 / 8.1 0.008 0 0.8 Example 5 27.2 / 8.0 0.009 0 0.8

[0100] From Table 2 and Figure 1-6 It can be seen that the compressive strength and flexural strength of the floor slab systems obtained in Examples 1-5 are better than those in Comparative Example 2, indicating that the floor slab systems obtained in Examples 1-5 have high stiffness. Among them, the stiffness of the leveling layer contributes the most to the stiffness of the floor slab system, which means that the stiffness of the leveling layer in Examples 1-5 is better than that in Comparative Example 2. Since the floor decoration layer is on top of the leveling layer, the leveling layer needs to bear the load. The higher the compressive and flexural strength of the leveling layer, the better, which can also effectively prevent hollow cracking. The shrinkage rate of the floor slab systems obtained in Examples 1-5 is significantly lower than that of Comparative Example 2, indicating that they are not prone to cracking. The floor slab systems obtained in Examples 1-5 have good anti-mildew properties and low water absorption.

[0101] This invention includes, but is not limited to, the above embodiments. Any equivalent substitutions or partial improvements made under the spirit and principles of this invention shall be considered within the scope of protection of this invention.

Claims

1. A gypsum-based sound-insulating and heat-insulating floor slab system with geothermal function, characterized in that: The floor system includes, from bottom to top, a structural layer, a sound insulation and heat insulation layer, a heat insulation layer, a heating layer, and a leveling layer; wherein, the sound insulation and heat insulation layer is composed of foamed gypsum-based composite material, the heat insulation layer is composed of heat insulation material, and the leveling layer is composed of moisture-proof and mildew-proof gypsum self-leveling mortar. The foamed gypsum-based composite material is composed of the following components in parts by weight: β-type building gypsum or α-type high-strength gypsum: 60-85 parts, retarding water-reducing agent: 0.06-0.12 parts, water: 30-50 parts, waterproofing agent: greater than 0 and less than or equal to 3 parts, composite foaming agent: 1-3 parts, lightweight aggregate: 5-15 parts; the composite foaming agent is composed of the following components in parts by weight: foam stabilizer: 0.1-0.5 parts, physical foaming agent: 8-10 parts, sodium sulfate: 0.1-0.3 parts; The thermal insulation material is composed of the following components in parts by weight: gypsum powder: 30-50 parts, hollow glass microspheres: 10-20 parts, retarding water-reducing agent: 3-5 parts, latex: 30-40 parts, titanium dioxide: 1-5 parts, thermal insulation material: 5-8 parts; wherein, the solid content of the latex is ≥35%; The moisture-proof and mildew-proof gypsum self-leveling mortar is composed of the following components in parts by weight: phosphogypsum or desulfurized gypsum: 100-120 parts, water: 35-50 parts, retarding water-reducing agent: 0.26-1.12 parts, waterproofing agent: 0.2-0.8 parts, and mildew inhibitor: 0.2-0.5 parts.

2. The gypsum-based sound insulation and heat-insulating floor slab system with geothermal function according to claim 1, characterized in that: The retarding water-reducing agent is composed of the following components in parts by weight: 90-100 parts of polycarboxylate-based mother liquor or melamine-based mother liquor, 9-20 parts of borax, 0.2-1.0 parts of retarder, 0-1.5 parts of cellulose ether, 0.1-0.2 parts of suspension stabilizer, 0.1-1 parts of defoamer, and 90-100 parts of water; The waterproofing agent comprises the following components in parts by weight: 1.5 to 2.8 parts sodium alkylsilicate, 2.0 to 3.9 parts stearic acid, 15.8 to 24.2 parts alum, 11.2 to 22.4 parts titanium dioxide, 75.0 to 100.0 parts cement, 150.0 to 200.0 parts mineral powder, and 0.5 to 1.0 parts hydroxyl-terminated modified hyperbranched polymer; The antifungal agent comprises the following components in parts by weight: 3 to 8 parts inorganic antibacterial component, 3 to 8 parts chitosan, 3 to 7 parts sodium methylsilicate, 4 to 14 parts silicone-acrylic emulsion, 0.2 to 2 parts pH adjuster, and 0.1 to 1 part sodium dodecyl sulfate; the inorganic antibacterial component comprises 1 to 3 parts nano silver, 1 to 3 parts borax, and 1 to 5 parts nano titanium dioxide.

3. A gypsum-based sound-insulating and heat-insulating floor system with geothermal function according to claim 1 or 2, characterized in that: The lightweight aggregate is one or more of the following: 80-100 mesh open-cell vitrified microspheres, 60-80 mesh open-cell perlite, 200-300 mesh aerated concrete, and 10-40 mesh ceramic ceramsite.

4. A gypsum-based sound-insulating and heat-insulating floor slab system with geothermal function according to claim 3, characterized in that: The density of the open-pore vitrified microspheres is 80 kg / m³. 3 ~120kg / m 3 The porous perlite has a density of 60 kg / m³ to 80 kg / m³, and the aerated concrete has a density of 32 kg / m³. 3 .

5. A gypsum-based sound-insulating and heat-insulating floor slab system with geothermal function according to claim 3, characterized in that: The lightweight aggregate is composed of the following components in parts by weight: 1 to 5 parts of 100-mesh open-cell vitrified microspheres and 5 to 10 parts of 30-mesh ceramic ceramsite; and the ceramic ceramsite has a porosity ≥18%, an adsorption rate ≥20%, a compressive strength ≥1MPa, and a sphericity ≥0.

95.

6. A gypsum-based sound-insulating and heat-insulating floor slab system with geothermal function according to claim 5, characterized in that: The ceramic granules are silver ion-containing graphene ceramic granules with a particle size of 3mm to 6mm, wherein silver ions and graphene are uniformly distributed on the surface and inside of the ceramic granules.

7. A gypsum-based sound-insulating and heat-insulating floor slab system with geothermal function according to claim 1 or 2, characterized in that: The floor system also includes a floor decoration layer placed above the leveling layer; the flooring in the floor decoration layer is wood flooring, stone, ceramic tiles, mosaic tiles, or composite flooring; When the floor is stone tile, ceramic tile or mosaic tile, an adhesive layer is laid under the floor. The adhesive layer is selected from polymer cement-based adhesive mortar, gypsum adhesive mortar or moisture-proof and mildew-proof gypsum adhesive mortar. When the flooring is wood flooring or composite flooring, a moisture-proof layer is laid under the flooring. The moisture-proof layer is made of pearl cotton, ethylene-vinyl acetate copolymer, electronically cross-linked polyethylene foam, plasticizer-free polyvinyl chloride, aluminum foil mat, or paper mat, with a thickness of 1.5mm to 2.5mm and a water absorption rate of ≤0.5%.

8. A gypsum-based sound-insulating and heat-insulating floor slab system with geothermal function according to claim 7, characterized in that: The bonding layer is a moisture-proof and mildew-proof gypsum bonding mortar with a thickness of 4mm to 6mm, a mildew resistance rating of 0, a pull-out bond strength of ≥1.5MPa, and a fire resistance rating of Class A.

9. A construction method for a gypsum-based sound-insulating and heat-insulating floor slab system with geothermal function as described in any one of claims 1 to 8, characterized in that: The steps of the method are as follows: (1) Clean the structural layers and determine the thickness of each layer; (2) Install vertical sound insulation strips at the corners of the walls and the thresholds; (3) Prepare a sound insulation and heat preservation layer on the cleaned structural layer using a wet or dry process; When using the wet process, the foamed gypsum-based composite material slurry, which is uniformly mixed and has a flowability of 120mm±3mm, is poured evenly onto the structural layer. When using the dry process, the prefabricated foamed gypsum-based composite material components with reserved pipe grooves are laid on the structural layer. The depth of the pipe groove is 1 / 2 to 2 / 3 of the diameter of the hot water pipe, and the joint width of the prefabricated components is less than 0.5 mm. (4) When using the wet process, after the foamed gypsum-based composite material slurry is poured for 0.5h to 1h, the heat insulation material is poured on it. After 1h to 2h after the pouring is completed, the heat insulation layer is obtained. Then, the pipes are laid to form the heating layer. Finally, the moisture-proof and mildew-proof gypsum self-leveling mortar is poured to form the leveling layer. When using the dry process, the heat insulation material is applied to the sound insulation and heat preservation layer, and the gaps between the prefabricated components are sealed at the same time. The heat insulation layer is obtained 0.5h to 1h after the heat insulation material is applied. Hot water pipes are embedded in the prefabricated components to form a heating layer. Then, moisture-proof and mildew-proof gypsum self-leveling mortar is poured to form a leveling layer. (5) The sound insulation and heat insulation layer, the heat insulation layer and the leveling layer are constructed continuously and naturally cured. After the leveling layer is poured and formed, the floor decoration layer is laid.

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