A porous ceramic particle sound-absorbing material and its preparation method

Abstract

This invention proposes a porous ceramic particle sound-absorbing material, comprising the following components in parts by weight: this material exhibits good sound absorption performance, low production cost, high strength, and strong aging resistance. This invention also proposes a method for preparing the porous ceramic particle sound-absorbing material.

Description

Technical Field

[0001] This invention relates to the field of sound-absorbing materials technology, specifically to a porous ceramic particle sound-absorbing material. Background Technology

[0002] Sound-absorbing materials are materials that can absorb sound waves and reduce or absorb sound. There are many types of sound-absorbing materials, among which porous sound-absorbing materials are the most widely researched and applied. Porous sound-absorbing materials utilize the numerous micropores and gaps within their structure to attenuate sound waves, primarily absorbing mid- to high-frequency sound waves. Porous sound-absorbing materials include organic fiber materials, inorganic fiber materials, metal fiber materials, polymer fiber materials, foamed plastics, and foamed metals, among others.

[0003] Currently available porous sound-absorbing materials generally suffer from drawbacks such as lack of fire resistance, poor corrosion resistance, susceptibility to moisture damage, dust generation during production, and high production costs. The purpose of this invention is to provide a material that can solve these problems. Summary of the Invention

[0004] To overcome the shortcomings of existing technologies, this invention proposes a porous ceramic particle sound-absorbing material that has good sound absorption effect, low production cost, high strength, and strong aging resistance.

[0005] To achieve the above objectives, the present invention provides a porous ceramic particle sound-absorbing material comprising the following components in parts by weight:

[0006]

[0007] Furthermore, the porous ceramic particles have a particle size of 2mm-6mm and comprise the following components in the following proportions:

[0008] Basic raw materials 40%-95%

[0009] Adjust raw material concentration by 4.5%-59.5%.

[0010] Foaming agent 0.5%.

[0011] Furthermore, the basic raw materials are one or more of the following: river and lake silt, granite processing powder, steelmaking waste slag, fly ash, coal gangue, iron tailings, gold tailings, lithium tailings, electrolytic aluminum red mud, shale, basalt, kaolin, ceramic processing powder, waste glass, water purification agent sludge, photovoltaic fluorine-containing sludge, printing and dyeing sludge, weathered sedimentary sand, and fly ash. The basic raw materials mainly contain silicon, aluminum, magnesium, calcium, etc., and are generally obtained at low cost or free of charge.

[0012] Furthermore, the adjusting raw materials include one or more of potassium feldspar, sodium feldspar, lithium feldspar, talc, quartz sand, bentonite, high-temperature flux, and iron oxide powder. These adjusting raw materials are used to regulate properties such as plasticity, fluidity, vitrification, thixotropy, sintering temperature, and color.

[0013] Furthermore, the foaming agent is one or more of calcium carbonate, graphite, and silicon carbide. The foaming agent occupies a certain space in the ceramic green body, which is then sintered at 1100℃. The foaming agent leaves the matrix and forms pores to prepare porous ceramics. The foaming agent undergoes gasification at different stages between 1000℃ and 1150℃.

[0014] Furthermore, the organic adhesive is made of epoxy resin, with a shear strength ≥12 MPa and a viscosity of 40,000 cps-45,000 cps at room temperature.

[0015] Furthermore, the mineral fiber comprises the following components in parts by weight:

[0016]

[0017] Alkaline earth oxides include CaO and MgO, while alkali metal oxides include Na2O and K2O.

[0018] Furthermore, the fineness of the colored sand particles is 50-120 mesh, and the colored sand is one or more of the following: natural colored sand, sintered colored sand, and permanently dyed colored sand.

[0019] This invention also proposes a method for preparing porous ceramic particle sound-absorbing material, comprising the following steps:

[0020] S1: To prepare porous ceramic particles, take each raw material component, mix them, sinter them at 1100℃, and then use a pulverizer and granulator to pulverize and granulate them.

[0021] S2: Screening porous ceramic particles using an industrial sieve to select porous ceramic particles with the required particle size.

[0022] S3: Mixing: Take organic glue and mineral fiber, mix them thoroughly with porous ceramic particles, and stir until they are in a uniform and loose state.

[0023] S4: Compression molding, pour the mixed material into the precast mold, cover the surface with colored sand, compact and smooth it;

[0024] S5: Air dry naturally, demold, and obtain the finished porous ceramic particle sound-absorbing material.

[0025] The porous ceramic particle sound-absorbing material of this invention uses porous ceramic particles as the substrate. The porous ceramic particles themselves have a porous structure, and small pores exist between the particles. Therefore, the sound-absorbing material has a higher porosity, resulting in better viscosity, internal friction, thermal conduction, and relaxation effects, significantly improving the sound absorption effect. The noise reduction coefficient can stably reach above 0.80, and with appropriate processing, it can reach above 0.86, which is superior to high-quality outdoor sound-absorbing materials on the market. Furthermore, using porous ceramic particles as the substrate makes the sound-absorbing material of this invention low in production cost, high in strength, and highly resistant to aging. Detailed Implementation

[0026] The technical solution of the present invention will be explained more clearly and completely below through the description of preferred embodiments.

[0027] Before preparing porous ceramic particle sound-absorbing materials, the porous ceramic particles are first prepared:

[0028] The basic raw materials, accounting for 40%-95%, are one or more of the following: river and lake silt, granite processing powder, steelmaking waste slag, fly ash, coal gangue, iron tailings, gold tailings, lithium tailings, electrolytic aluminum red mud, shale, basalt, kaolin, ceramic processing powder, waste glass, water purification agent sludge, photovoltaic fluorine-containing sludge, printing and dyeing sludge, weathered sedimentary sand, and fly ash.

[0029] The adjusting raw materials, accounting for 4.5%-59.5%, are one or more of potassium feldspar, sodium feldspar, lithium feldspar, talc, quartz sand, bentonite, high-temperature flux, and iron oxide powder.

[0030] The foaming agent, comprising 0.5%, is one or more of calcium carbonate, graphite, and silicon carbide.

[0031] The ingredients are mixed and then sintered at 1100℃. After firing, they are crushed and granulated using a pulverizer and then screened with a specific aperture industrial sieve to obtain porous ceramic particles with a particle size of 2mm-6mm.

[0032] Alternatively, commercially available porous ceramic particles can be purchased and used.

[0033] Example 1: Preparation of porous ceramic particle sound-absorbing material:

[0034] By weight, take 100 parts of porous ceramic particles with a particle size of 2mm, add 4 parts of mineral fiber and 30 parts of organic glue, and stir until uniform and loose; pour the mixture into a precast mold, cover the surface with 1 part of colored sand and smooth it; use a pressure device to compact the mixture into shape, and after natural air drying, obtain porous ceramic particle sound-absorbing material with a thickness of 45mm and a weight of 240g.

[0035] The mineral fibers include the following components by weight: 40 parts SiO2, 15 parts Al2O3, 3 parts Fe2O3, 25 parts CaO and MgO, and 3 parts Na2O and K2O.

[0036] Example 2: Preparation of porous ceramic particle sound-absorbing material:

[0037] By weight, take 100 parts of porous ceramic particles with a particle size of 3mm, add 4 parts of mineral fiber and 30 parts of organic glue, and stir until uniform and loose; pour the mixture into a precast mold, cover the surface with 1 part of colored sand and smooth it; use a pressure device to compact the mixture into shape, and after natural air drying, obtain porous ceramic particle sound-absorbing material with a thickness of 40mm and a weight of 183g.

[0038] The mineral fibers include the following components by weight: 60 parts SiO2, 25 parts Al2O3, 7 parts Fe2O3, 30 parts CaO and MgO, and 6 parts Na2O and K2O.

[0039] Example 3: Preparation of porous ceramic particle sound-absorbing material:

[0040] By weight, take 100 parts of porous ceramic particles with a particle size of 2mm, add 4 parts of mineral fiber and 20 parts of organic glue, and stir until uniform and loose; pour the mixture into a precast mold, cover the surface with 1 part of colored sand and smooth it; use a pressure device to compact the mixture into shape, and after natural air drying, obtain porous ceramic particle sound-absorbing material with a thickness of 25mm and a weight of 143g.

[0041] The mineral fibers include the following components by weight: 54 parts SiO2, 15 parts Al2O3, 3 parts Fe2O3, 25 parts CaO and MgO, and 3 parts Na2O and K2O.

[0042] Example 4: Preparation of porous ceramic particle sound-absorbing material:

[0043] By weight, take 100 parts of porous ceramic particles with a particle size of 5mm, add 4 parts of mineral fiber and 30 parts of organic glue, and stir until uniform and loose; pour the mixture into a precast mold, cover the surface with 1 part of colored sand and smooth it; use a pressure device to compact the mixture into shape, and after natural air drying, obtain porous ceramic particle sound-absorbing material with a thickness of 25mm and a weight of 75g.

[0044] The mineral fibers include the following components by weight: 50 parts SiO2, 20 parts Al2O3, 5 parts Fe2O3, 28 parts CaO and MgO, and 4 parts Na2O and K2O.

[0045] Example 5: Preparation of porous ceramic particle sound-absorbing material:

[0046] By weight, take 50 parts of porous ceramic particles with a particle size of 2mm and 50 parts of porous ceramic particles with a particle size of 5mm, add 4 parts of mineral fiber and 30 parts of organic glue, and stir until uniform and loose; pour the mixture into a precast mold, spread 2 parts of colored sand on the surface and smooth it; use a pressure device to compact the mixture into shape, and after natural air drying, obtain porous ceramic particle sound-absorbing material with a thickness of 25mm and a weight of 74g.

[0047] The mineral fibers include the following components by weight: 48 parts SiO2, 17 parts Al2O3, 5 parts Fe2O3, 26 parts CaO and MgO, and 4 parts Na2O and K2O.

[0048] For the sound absorption test, the porous ceramic particle sound-absorbing materials obtained in Examples 1-5 were respectively used to form test samples with a 100mm cavity. The sound absorption performance was tested using a standing wave tube. The test data are shown in Table 1.

[0049] Table 1: Sound Absorption Test Data

[0050]

[0051]

[0052] Based on the above embodiments and test results, it can be seen that the porous ceramic particle sound-absorbing material of the present invention has a good sound absorption effect on noise, and the noise reduction coefficient can be stably reached above 0.80. With the process matching, the noise reduction coefficient NRC can be reached above 0.86.

[0053] The porous ceramic particle sound-absorbing material of this invention uses porous ceramic particles as the substrate. The porous ceramic particles themselves have a porous structure, and small pores exist between the particles. Therefore, the sound-absorbing material has a higher porosity, resulting in better viscosity, internal friction, thermal conduction, and relaxation effects, significantly improving the sound absorption effect. The noise reduction coefficient can stably reach above 0.80, and with appropriate processing, it can reach above 0.86, which is superior to high-quality outdoor sound-absorbing materials on the market. Furthermore, using porous ceramic particles as the substrate makes the sound-absorbing material of this invention low in production cost, high in strength, and highly resistant to aging.

[0054] The above-described specific embodiments are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Various modifications, substitutions, and improvements made by those skilled in the art to the technical solutions of the present invention based on the provided description, without departing from the design concept and spirit of the present invention, should all fall within the scope of protection of the present invention. The scope of protection of the present invention is determined by the claims.

Claims

1. A porous ceramic particle sound-absorbing material, characterized in that, The components include the following parts by weight: 100 parts of porous ceramic particles 20-30 parts organic glue 3-5 parts mineral fiber 1-2 parts colored sand; The porous ceramic particles have a particle size of 2mm-6mm and comprise the following components in the following proportions: Basic raw materials 40%-95% Adjust raw material concentration by 4.5%-59.5%. Foaming agent 0.5%; The organic adhesive is an epoxy resin adhesive with a shear strength ≥12MPa and a viscosity of 40000cps-45000cps at room temperature. The mineral fiber comprises the following components in parts by weight: 40-60 parts SiO2 Al2O3 15-25 parts Fe2O3 3-7 parts 25-30 parts of alkaline earth oxides 3-6 parts of alkali metal oxides; The alkaline earth oxides include CaO and MgO, and the alkali metal oxides include Na2O and K2O. The fineness of the colored sand particles is 50-120 mesh, and the colored sand is one or more of natural colored sand, sintered colored sand, and permanently dyed colored sand. The preparation method of porous ceramic particle sound-absorbing material includes the following steps: S1: To prepare porous ceramic particles, take each raw material component, mix them, sinter them at 1100℃, and then use a pulverizer and granulator to pulverize and granulate them. S2: Screening porous ceramic particles using an industrial sieve to select porous ceramic particles with the required particle size. S3: Mixing: Take organic glue and mineral fiber, mix them thoroughly with porous ceramic particles, and stir until they are in a uniform and loose state. S4: Compression molding, pour the mixed material into the precast mold, cover the surface with colored sand, compact and smooth it; S5: Air dry naturally, demold, and obtain the finished porous ceramic particle sound-absorbing material.

2. The porous ceramic particle sound-absorbing material according to claim 1, characterized in that, The basic raw materials are one or more of the following: river and lake silt, granite processing powder, steelmaking waste slag, fly ash, coal gangue, iron tailings, gold tailings, lithium tailings, electrolytic aluminum red mud, shale, basalt, kaolin, ceramic processing powder, waste glass, water purification agent sludge, photovoltaic fluorine-containing sludge, printing and dyeing sludge, weathered sedimentary sand, and fly ash.

3. The porous ceramic particle sound-absorbing material according to claim 1, characterized in that, The conditioning raw materials are one or more of potassium feldspar, sodium feldspar, lithium feldspar, talc, quartz sand, bentonite, and iron oxide powder.

4. The porous ceramic particle sound-absorbing material according to claim 2, characterized in that, The foaming agent is one or more of calcium carbonate, graphite, and silicon carbide.

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