Sound-absorbing, heat-insulating, decorative integrated composite perforated sandwich aluminum plate and manufacturing method thereof

Abstract

The application discloses a sound-absorbing heat-insulating decoration integrated composite through-hole sandwich aluminum plate and a manufacturing method thereof. The sound-absorbing heat-insulating decoration integrated composite through-hole sandwich aluminum plate comprises a three-dimensional micro-through-hole sound-absorbing aluminum plate, composite fiber sound-absorbing non-woven fabric, a honeycomb aluminum interlayer and a heat-insulating cotton plate. The three-dimensional micro-through-hole sound-absorbing aluminum plate body is formed into an aluminum buckle plate form structure with cavities by twice bending. The composite fiber sound-absorbing non-woven fabric is arranged in the cavities and on the three-dimensional micro-through-hole sound-absorbing aluminum plate. The cavities are sequentially filled from inside to outside with the honeycomb aluminum interlayer and the heat-insulating cotton plate. The special three-dimensional micro-punching process is adopted for the decoration aluminum plate, so that the aluminum plate itself has good sound-absorbing function. The new high-efficiency sound-absorbing non-woven fabric is used to reduce the use of sound-absorbing fiber cotton. While the performance requirement is ensured, the interior decoration layer structure is simplified, the construction efficiency is improved, the engineering cost is reduced, and the functionality and convenience of the composite through-hole aluminum plate are greatly improved.

Description

Technical Field

[0001] This invention relates to the field of manufacturing technology, specifically to an integrated sound-absorbing, heat-insulating, and decorative composite through-hole sandwich aluminum plate and its manufacturing method. Background Technology

[0002] In places such as computer rooms, conference rooms, exhibition halls, and cinemas, there are high requirements for the sound absorption and thermal insulation performance of interior decoration. The conventional approach to interior decoration is to construct the insulation layer, sound absorption layer, and decorative layer separately, which has problems such as complicated procedures, large thickness of decorative layer occupying indoor space, and heavy weight placing high demands on the structural keel.

[0003] From a material perspective, mineral fiber materials such as rock wool and glass fiber wool are the most widely used sound-absorbing and heat-insulating materials. These fiber materials have good sound absorption effects, but they also have problems such as being difficult to construct, easily absorbing moisture, and easily weathering. After the fiber materials absorb moisture and become damp, their sound absorption and heat insulation performance deteriorates, and the weathered fiber particles are released into the air, which is not good for health and the environment.

[0004] In addition, while organic insulation boards such as XPS extruded polystyrene boards and polyurethane boards have good thermal insulation properties, they also have drawbacks when used as indoor insulation materials, such as poor fire resistance and the release of toxic gases at high temperatures. Therefore, the development of efficient, safe, aesthetically pleasing, and convenient integrated sound-absorbing, thermally insulating, and decorative interior panels has significant engineering implications and broad application scenarios.

[0005] Perforated aluminum panels are widely used in interior wall and ceiling decoration panels due to their advantages such as being lightweight, aesthetically pleasing, durable, and recyclable. However, conventional perforated aluminum panels have straight perforations, which allow sound to pass through, but they have almost no sound absorption effect on their own and need to be used in conjunction with sound-absorbing cotton. Therefore, existing perforated aluminum panels have poor sound absorption and complex application structures, which greatly reduces their reliability.

[0006] Therefore, improving the reliability of perforated aluminum plates is a problem that needs to be solved in this field. Summary of the Invention

[0007] To address the technical problem of low reliability in existing perforated aluminum panels, the present invention aims to provide an integrated sound-absorbing, heat-insulating, and decorative composite perforated sandwich aluminum panel. This aluminum panel combines sound absorption, heat insulation, and decorative functions, while simplifying the interior layer structure, improving construction efficiency, and reducing project costs, all while ensuring performance requirements. Furthermore, a method for manufacturing the integrated sound-absorbing, heat-insulating, and decorative composite perforated sandwich aluminum panel is provided, effectively overcoming the problems existing in the prior art.

[0008] To achieve the above objectives, the present invention provides an integrated sound-absorbing, heat-insulating, and decorative composite perforated sandwich aluminum panel, comprising a three-dimensional micro-perforated sound-absorbing aluminum panel, a composite fiber sound-absorbing non-woven fabric, a honeycomb aluminum interlayer, and a heat-insulating cotton board. The three-dimensional micro-perforated sound-absorbing aluminum panel body is formed into an aluminum buckle panel structure with an internal cavity by bending twice. The composite fiber sound-absorbing non-woven fabric is located in the cavity and disposed on the three-dimensional micro-perforated sound-absorbing aluminum panel. The cavity is filled with the honeycomb aluminum interlayer and the heat-insulating cotton board sequentially from the inside to the outside.

[0009] Furthermore, the first and second surfaces of the three-dimensional micro-perforated sound-absorbing aluminum plate are each provided with a plurality of recessed first conical punches and second conical punches, which are connected by through holes.

[0010] Furthermore, the first and second tapered punches are three-dimensional inverted tapered shapes.

[0011] Furthermore, the tapered height of the first and second tapered punches is 70% ± 2% of the total thickness of the three-dimensional micro-perforated sound-absorbing aluminum plate.

[0012] Furthermore, the total area of ​​the bottom openings of the plurality of first conical punches or the plurality of second conical punches is approximately 70% to 85% of the total area of ​​the first or second surface of the three-dimensional micro-perforated sound-absorbing aluminum plate.

[0013] Furthermore, the total area of ​​the through holes is 20% to 30% of the area of ​​the three-dimensional micro-perforated sound-absorbing aluminum plate.

[0014] Furthermore, the three-dimensional micro-perforated sound-absorbing aluminum plate is coated with a colored coating, and the surface treatment process is electrostatic spraying or anodizing.

[0015] Furthermore, the composite fiber sound-absorbing nonwoven fabric is a glass fiber + wood fiber composite fiber nonwoven fabric.

[0016] Furthermore, the embossed aluminum foil is glued to one side of the insulation board and then filled into the cavity formed by the three-dimensional micro-perforated sound-absorbing aluminum fold, with the side of the insulation board without aluminum foil facing the honeycomb aluminum interlayer.

[0017] To achieve the above objectives, the present invention provides a method for manufacturing an integrated sound-absorbing, heat-insulating, and decorative composite through-hole sandwich aluminum plate, the method comprising the following steps:

[0018] (1) A three-dimensional micro-perforated sound-absorbing aluminum plate is prepared by double-sided punching of aluminum alloy plate using a mold hydraulic punching method;

[0019] (2) Cut three-dimensional micro-hole sound-absorbing aluminum plates according to the size of sandwich panels. After cutting out rectangular sections at the four corners, bend the plates. Cut the corners of the plates at a 45° angle to make the plates tightly fitted together.

[0020] (3) Use aluminum alloy cold working equipment to bend the cut three-dimensional micro-perforated sound-absorbing aluminum plate, bend each side twice to form an aluminum plate square box of the designed size.

[0021] (4) The surface of the three-dimensional micro-perforated sound-absorbing aluminum plate is treated according to the decoration design requirements, and the material is composited after the coating is dried and fixed.

[0022] (5) Adhesive-backed composite fiber sound-absorbing non-woven fabric is pasted onto the back of the three-dimensional micro-perforated sound-absorbing aluminum plate and heated with an electric iron to improve the bonding ability of the hot melt resin adhesive.

[0023] (6) After fully unfolding the honeycomb aluminum sandwich layer, cut it to a size slightly smaller than the design size of the sandwich panel, fill it into the cavity of the three-dimensional micro-perforated sound-absorbing aluminum plate square box, place it on the back of the composite fiber sound-absorbing non-woven fabric, and glue the edge strips formed by cutting the honeycomb aluminum to the inner sidewall of the cavity of the three-dimensional micro-perforated sound-absorbing aluminum plate square box with structural adhesive.

[0024] (7) The insulation board is bonded to the aluminum foil board with structural adhesive on one side and embossed. Then it is stuffed into the cavity of the three-dimensional micro-perforated sound-absorbing aluminum plate square box to fill it. The side of the aluminum foil without embossing faces the three-dimensional micro-perforated sound-absorbing aluminum plate and forms a composite through-hole sandwich aluminum plate with honeycomb aluminum interlayer, composite fiber sound-absorbing non-woven fabric and three-dimensional micro-perforated sound-absorbing aluminum plate.

[0025] The present invention provides an integrated sound-absorbing, heat-insulating, and decorative composite perforated sandwich aluminum plate and its manufacturing method. The perforated aluminum plate adopts a special three-dimensional micro-punching process, which enables the aluminum plate itself to have good sound absorption function. The composite new high-efficiency sound-absorbing non-woven fabric reduces the use of sound-absorbing fiber cotton. While ensuring performance requirements, it simplifies the structure of the interior layer, improves construction efficiency, reduces project costs, and greatly improves the reliability of the perforated aluminum plate. Attached Figure Description

[0026] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0027] Figure 1 This is a schematic diagram of the overall structure of the integrated sound-absorbing, heat-insulating, and decorative perforated sandwich aluminum panel.

[0028] Figure 2 This is an exploded view of the overall structure of the sound-absorbing, heat-insulating, and decorative integrated perforated sandwich aluminum panel.

[0029] Figure 3 for Figure 1 A schematic diagram of the structure of a three-dimensional micro-perforated sound-absorbing aluminum plate.

[0030] The following are the component labels in the attached diagram:

[0031] 100. Three-dimensional micro-perforated sound-absorbing aluminum plate; 110. Conical perforation; 120. Through hole; 200. Composite fiber sound-absorbing non-woven fabric; 300. Honeycomb aluminum sandwich; 400. Thermal insulation cotton board; 500. Embossed aluminum foil board. Detailed Implementation

[0032] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below with reference to specific illustrations.

[0033] To address the technical problem of low reliability in existing perforated aluminum panels, the present invention aims to provide an integrated sound-absorbing, heat-insulating, and decorative composite through-hole sandwich aluminum panel. The through-hole decorative aluminum panel employs a special three-dimensional micro-perforation process, giving the aluminum panel itself excellent sound absorption capabilities. A novel high-efficiency sound-absorbing non-woven fabric is then incorporated to reduce the need for sound-absorbing fiber cotton. While ensuring performance requirements are met, this invention simplifies the interior layer structure, improves construction efficiency, reduces project costs, and significantly enhances the reliability of the perforated aluminum panel.

[0034] The sound-absorbing, heat-insulating, and decorative integrated composite perforated sandwich aluminum plate provided by this invention is described in [reference needed]. Figures 1-2 It includes a three-dimensional micro-perforated sound-absorbing aluminum panel 100, a composite fiber sound-absorbing non-woven fabric 200, a honeycomb aluminum sandwich layer 300, a thermal insulation cotton board 400, and an embossed aluminum foil board 500. The three-dimensional micro-perforated sound-absorbing aluminum panel 100, the composite fiber sound-absorbing non-woven fabric 200, the honeycomb aluminum sandwich layer 300, the thermal insulation cotton board 400, and the embossed aluminum foil board 500 are combined to form an integrated thermal insulation and decorative composite perforated sandwich aluminum panel. It can be used for ceiling installation with triangular lightweight keel or for interior wall installation without keel connection. The panel surface is flat and the installation is convenient.

[0035] Furthermore, the substrate of the three-dimensional micro-perforated sound-absorbing aluminum plate 100 in this solution is preferably an aluminum alloy plate. The sound-absorbing aluminum plate is non-combustible and has a high fire resistance rating, reaching GB8642 B1 level.

[0036] The three-dimensional micro-perforated sound-absorbing aluminum plate 100 can be folded twice to form an aluminum buckle panel structure with an internal cavity. After the two folds, a front plate and a rear plate can be formed. The cavity formed between the front plate and the rear plate can be used to install composite fiber sound-absorbing non-woven fabric 200, honeycomb aluminum interlayer 300, thermal insulation cotton board 400, and embossed aluminum foil board 500. At the same time, the inflection point of the two folds can limit / fix the composite fiber sound-absorbing non-woven fabric, honeycomb aluminum interlayer 300, thermal insulation cotton board 400, and embossed aluminum foil board 500 placed in the cavity.

[0037] See Figure 3Conical punches 110 are provided on the surface of the three-dimensional micro-perforated sound-absorbing aluminum plate 100. Specifically, the first and second surfaces of the three-dimensional micro-perforated sound-absorbing aluminum plate 100 are respectively provided with recessed first conical punches and second conical punches. The first conical punches and second conical punches are three-dimensional inverted cones.

[0038] It should be noted that the thickness of the three-dimensional micro-perforated sound-absorbing aluminum plate 100 is approximately 1.4mm to 1.6mm, the height of the triangular pyramids of the first and second conical punches is approximately 70% ± 2% of the thickness of the sound-absorbing aluminum plate 100, the surface aperture of the conical three-dimensional punch 110 is 0.9mm to 1.1mm, and the total area of ​​the triangular base of the conical three-dimensional punch accounts for approximately 70% to 85% of the surface area of ​​the sound-absorbing aluminum plate.

[0039] In this design, the thickness of the three-dimensional micro-perforated sound-absorbing aluminum plate 100 is preferably 1.5 mm. The height of the triangular pyramids of the first and second conical punches is approximately 1.05 mm, which is about 70% of the total thickness of the three-dimensional micro-perforated sound-absorbing aluminum plate 100. Meanwhile, the surface aperture of the triangular pyramid three-dimensional punch 110 is preferably about 1.0 mm. The total area of ​​the triangular triangles on the bottom surface of the triangular pyramid three-dimensional punch accounts for about 70% of the area of ​​the sound-absorbing aluminum plate. This preferred value ensures that most of the sound waves reaching the surface of the aluminum plate can be absorbed by the triangular pyramid through holes of the aluminum plate.

[0040] The first tapered punch on the first surface and the second tapered punch on the second surface are respectively provided, and the first tapered punch and the second tapered punch penetrate each other to form a through hole at the middle position of the plate thickness.

[0041] It should be noted that the diameter of the through holes 120 is approximately between 0.2mm and 0.3mm, and the total area of ​​the through holes accounts for approximately 20% to 30% of the area of ​​the sound-absorbing aluminum plate.

[0042] In this design, the diameter of the elliptical micro-hole 120 is preferably 0.3 mm, which accounts for about 25% of the total length between the first triangular pyramid punch and the second triangular pyramid punch. This preferred value can further ensure the penetration rate of sound waves.

[0043] Furthermore, in order to ensure the sound absorption effect of the three-dimensional micro-perforated sound-absorbing aluminum plate 100, the three-dimensional micro-perforated sound-absorbing aluminum plate 100 is folded twice to form an aluminum buckle plate structure with a cavity. When there is a cavity behind the three-dimensional micro-perforated sound-absorbing aluminum plate 100, a cavity sound absorption effect can be generated. The sound absorption coefficient is related to the thickness of the cavity behind the plate. Moisture or dust accumulation will affect the sound absorption performance of the perforated aluminum plate.

[0044] Therefore, when the cavity width formed between the three-dimensional micro-perforated sound-absorbing aluminum plates 100 is about 85mm-95mm, the NRC sound absorption coefficient is about 0.70. Under the conditions of water spraying and dust spraying, the sound absorption coefficient is about 0.60, which can achieve a good sound absorption effect and improve the sound absorption performance of this device.

[0045] In this solution, the existing large-diameter straight perforations are replaced with small and dense tapered perforations 110. The tapered perforations 110 will form micro-cavities that are larger on the outside and smaller on the inside on both sides of the aluminum plate. The tapered tips on both sides penetrate to form through holes 120 in the middle of the plate thickness. Unlike ordinary large-diameter straight perforated aluminum plates that have basically no sound absorption performance, this three-dimensional micro-perforated sound-absorbing aluminum plate 100 has good sound absorption performance.

[0046] Specifically, the use of tapered perforations 110 allows sound waves to enter the tapered perforations 110 (larger on the outside and smaller on the inside) and undergo multiple reflections on the inner wall of the perforation, thus dissipating some of the sound and achieving a sound absorption effect. The tapered bottom surface accounts for 70% to 85% of the entire three-dimensional micro-perforated sound-absorbing aluminum plate 100, which can absorb most of the sound waves that reach the plate surface into the cavity.

[0047] Sound waves that are not dissipated in the cavity will penetrate into the cavity through the small through hole 120. Since the second conical punch is larger on the outside and smaller on the inside, the sound waves that have penetrated into the cavity are difficult to be reflected out, thus achieving a sound absorption effect.

[0048] This solution does not limit the structure of the tapered punch 110, but prefers to use triangular cone punching, as the triangular cone punching process is easier to implement and the quality is more guaranteed.

[0049] Meanwhile, according to the decorative design requirements, the surface of the three-dimensional micro-perforated sound-absorbing aluminum plate 100 can be preferably treated by electrostatic spraying. Electrostatic spraying or oxidation coloring can be used to control the coating thickness and quality. After the coating dries and fixes, the material can be composited. This ensures the convenience of subsequent material composites.

[0050] Furthermore, the composite fiber sound-absorbing nonwoven fabric 200 is pasted on the inner side of the three-dimensional micro-perforated sound-absorbing aluminum plate 100. The composite fiber sound-absorbing nonwoven fabric 200 is used to enhance the sound absorption effect of the integrated sound-absorbing, heat-insulating and decorative composite perforated sandwich aluminum plate.

[0051] Here, the composite fiber sound-absorbing non-woven fabric 200 only needs to be pasted on the inner side of the vertical panel of the three-dimensional micro-perforated sound-absorbing aluminum plate 100. It is not necessary to avoid the tapered perforation 110 when pasting, as its self-adhesive backing will not block the tapered perforation 110.

[0052] Furthermore, the composite fiber sound-absorbing nonwoven fabric 200 in this scheme is preferably a glass fiber + wood fiber composite nonwoven fabric, with a thickness of approximately 0.2mm to 0.4mm and a specific gravity of 60g / m³. 2~70g / m 2 Between 2% and 4% elongation, the NRC sound absorption coefficient of the composite perforated aluminum plate is approximately between 0.6 and 0.80. Furthermore, the composite fiber sound-absorbing nonwoven fabric 200 in this solution preferably has a thickness of 0.3 mm and a surface density preferably of 65 g / m². 2 The preferred elongation rate is 3%. The preferred value of the above-mentioned composite fiber sound-absorbing nonwoven fabric 200 enables the integrated sound-absorbing, heat-insulating and decorative composite through-hole sandwich aluminum plate to have the characteristics of being lightweight and having good sound absorption effect. At the same time, the 3% elongation rate indicates that the nonwoven fabric has a certain tensile deformation capacity, which is beneficial to the nonwoven fabric bonding, but will not produce excessive deformation that affects the quality and appearance.

[0053] Furthermore, the composite fiber sound-absorbing nonwoven fabric 200 has a built-in hot-melt resin adhesive backing, which can be quickly adhered to the inner side of the three-dimensional micro-perforated sound-absorbing aluminum plate 100 after being heated to 70-90°C with an iron. In this solution, heating to 70°C is preferred, as heating to 70°C can improve the interfacial adhesion.

[0054] At the same time, due to the inherent properties of the composite fiber sound-absorbing nonwoven fabric 200, it also has excellent flame retardancy and fire resistance reaches GB8624 A2 level.

[0055] Furthermore, the honeycomb aluminum sandwich 300 is fully stretched and cut to a size slightly smaller than the design size of this sandwich panel. It is then closely attached to the composite fiber sound-absorbing non-woven fabric 200 and filled into the cavity of the three-dimensional micro-perforated sound-absorbing aluminum plate 100. The sides are bonded to the inner side wall of the cavity with structural adhesive to improve the overall rigidity and strength of the sandwich panel.

[0056] In this design, the substrate of the honeycomb aluminum interlayer 300 is preferably pure aluminum or aluminum alloy, which is non-combustible and has a fire resistance rating of GB8624 A1.

[0057] This solution does not limit the specifications of the 300mm honeycomb aluminum sandwich layer; the selection should be based on the specific specifications of the composite sandwich panel.

[0058] As an example, if the composite sandwich panel in this solution has a size of 600mm*600mm*40mm, the preferred thickness of the honeycomb aluminum sandwich layer 300 is 8mm. With this thickness, the side length of the honeycomb aperture is about 6mm in conventional sizes, which provides better stability and aesthetics. Moreover, with this size, the cavity of the panel is divided into several regular hexagonal columns with a side length of 6mm and a height of 8mm. The height-to-width ratio is appropriate, and the small space of the panel thickness can increase the number of sound wave reflections and improve the sound absorption effect.

[0059] The specific structure of the honeycomb aluminum interlayer 300 is well known to those skilled in the art, and will not be described in detail here.

[0060] Furthermore, the insulation cotton board 400 is glued to one side of the embossed aluminum foil board 500 and then filled into the cavity formed by the folding of the three-dimensional micro-perforated sound-absorbing aluminum plate 100, wherein the side without aluminum foil faces the honeycomb aluminum interlayer 300.

[0061] The 400mm insulation board has a thick embossed aluminum foil 500mm plate glued to the back, which can improve the waterproof and thermal insulation performance of the 400mm insulation board.

[0062] Furthermore, in this design, the 400 insulation board preferentially uses nitrile rubber (NBR) foam insulation board. Its foam structure is a closed-cell structure with a density of only about 70kg / m³ to 80kg / m³, a comprehensive thermal conductivity K-value of approximately 0.02W / (m·K) to 0.04W / (m·K), an operating temperature range of -40℃ to 120℃, a water absorption rate of less than 6%, a dimensional shrinkage rate of less than 3%, and fire resistance reaching GB8642 B1 non-combustible level. The smoke toxicity during combustion is AQ safety level. Therefore, the insulation panel is lightweight, which helps reduce the weight of the composite sandwich panel. The low thermal conductivity indicates good insulation performance; the thermal conductivity of this board is lower than that of common EPS, XPS, and rock wool insulation boards. Its operating temperature is suitable for all non-extreme environments. Regarding insulation board performance, it is not prone to moisture absorption or deformation. Its fire resistance reaches the non-combustible level, it does not release toxic gases at high temperatures, and it also has a certain sound absorption effect.

[0063] Nitrile rubber (NBR) foam insulation boards with embossed aluminum foil have a certain degree of deformation capability. When filling the three-dimensional micro-perforated sound-absorbing aluminum plate square box, any right angle should be inserted first, followed by the two sides of the right angle, and finally the diagonal, to reduce the bending deformation of the insulation board.

[0064] Meanwhile, the insulation board 400 is not limited to nitrile rubber, and can also be replaced with glass fiber wool board, rock wool board, polyurethane (PU) foam board, gold board and other insulation materials according to the insulation requirements.

[0065] The embossed aluminum foil 500 is preferably made of aluminum alloy film, which can be bonded to the back of the insulation board 400 by hot melt resin adhesive. The embossing process improves the bonding performance between the aluminum foil and the insulation board 400.

[0066] In summary, the sound-absorbing, heat-insulating, and decorative integrated composite perforated sandwich aluminum plate constructed in the above-described manner has a surface porosity of 70% to 85% in the three-dimensional micro-perforated sound-absorbing aluminum plate. This means that most of the sound waves reaching the surface of the aluminum plate are absorbed rather than reflected. The absorbed sound waves are partially absorbed and dissipated after multiple reflections within the conical cavity, while the remaining sound waves penetrate through the micro-perforations into the cavity behind the aluminum plate. In contrast, with the triangular pyramidal structure that is larger on the outside and smaller on the inside, sound waves are not easily able to penetrate out of the cavity behind the plate.

[0067] Secondly, the composite fiber sound-absorbing non-woven fabric is a porous fiber material. After sound waves penetrate, they are reflected and rubbed against the pores of the fiber material, which is converted into heat energy to achieve the sound absorption effect.

[0068] Meanwhile, the main purpose of the honeycomb aluminum sandwich 300 is to improve the overall rigidity and strength of the sandwich panel, but it divides the cavity behind the aluminum plate into several regular hexagonal columnar cavities, shortens the sound wave reflection distance, improves the reflection efficiency, and thus enhances the overall cavity sound absorption effect of the sandwich panel.

[0069] In addition, the main function of the 400 insulation board is heat preservation, but it is also a porous material and has a certain sound absorption effect.

[0070] In summary, by combining three-dimensional micro-perforated sound-absorbing aluminum plate 100, composite fiber sound-absorbing non-woven fabric 200, honeycomb aluminum sandwich 300, and thermal insulation cotton board 400, the sound absorption effect of the integrated sound-absorbing, heat-insulating, and decorative composite perforated sandwich aluminum plate is improved in multiple dimensions.

[0071] The sound-absorbing, heat-insulating, and decorative integrated perforated sandwich aluminum panel constructed using the above-mentioned scheme, through a special punching process for the sound-absorbing aluminum panel and the composite of high-performance functional materials, enables the integrated sound-absorbing, heat-insulating, and decorative composite perforated sandwich aluminum panel to have sound absorption, heat insulation, and decorative functions. It also features aesthetics, lightweight, flame retardancy, safety, stability, durability, and environmental friendliness. This achieves functional integration and performance enhancement of building interior panels, effectively simplifies construction procedures and installation processes, and has significant economic and engineering benefits.

[0072] Based on the above-mentioned integrated composite through-hole sandwich aluminum plate, the following example illustrates its manufacturing method in a specific application. This manufacturing scheme is only an example and does not constitute a limitation on this scheme. The manufacturing method includes the following steps:

[0073] (1) A three-dimensional micro-hole sound-absorbing aluminum plate 100 was prepared by double-sided punching of aluminum alloy plate using a mold hydraulic punching method;

[0074] (2) Cut a 100mm three-dimensional micro-hole sound-absorbing aluminum plate according to the size of the sandwich panel. After cutting out the rectangles at the four corners, bend the plate. Cut the corners of the plate at a 45° angle to make the plate tightly fit the edges.

[0075] (3) Use aluminum alloy cold working equipment to bend the cut three-dimensional micro-hole sound-absorbing aluminum plate 100. Each side is bent twice. The bending width is divided into the edge width and the thickness of the sandwich panel to form an aluminum plate square box of the designed size.

[0076] (4) The surface of the three-dimensional micro-perforated sound-absorbing aluminum plate 100 is treated according to the decoration design requirements, and the material is composited after the coating is dried and fixed.

[0077] (5) Adhesive-backed composite fiber sound-absorbing nonwoven fabric 200 is pasted onto the back of three-dimensional micro-perforated sound-absorbing aluminum plate 100 and heated with an electric iron to improve the bonding ability of hot melt resin adhesive.

[0078] (6) After fully unfolding the honeycomb aluminum sandwich 300, cut it to a size slightly smaller than the design size of the sandwich panel and fill it into the cavity of the three-dimensional micro-perforated sound-absorbing aluminum plate 100 square box. Place it on the back of the composite fiber sound-absorbing non-woven fabric 200. The edge strips formed by cutting the honeycomb aluminum are glued to the inner side wall of the cavity of the three-dimensional micro-perforated sound-absorbing aluminum plate 100 square box with structural adhesive.

[0079] (7) Cut a certain thickness of nitrile rubber (NBR) foam insulation board 400 to a size slightly smaller than the design size of the sandwich panel, and use structural adhesive to bond aluminum foil board 500 on one side and perform embossing to improve the bonding performance between aluminum foil and nitrile rubber (NBR) foam insulation board.

[0080] (8) Insert the nitrile rubber (NBR) foam insulation board 400 with embossed aluminum foil into the cavity of the three-dimensional micro-perforated sound-absorbing aluminum plate 100 square box to fill it, with the side without embossed aluminum foil facing the three-dimensional micro-perforated sound-absorbing aluminum plate 100.

[0081] (9) Install corner bracket connectors on the four sides of the sound-absorbing, heat-insulating and decorative composite through-hole sandwich aluminum panel so that it can be connected to the wall without keel by anchor bolts; or stamp aluminum buckle panels on the back edge aluminum panel and connect them with light triangular keel for use as indoor ceiling.

[0082] The sound-absorbing, heat-insulating, and decorative integrated perforated sandwich aluminum plate and its manufacturing method, constructed using the above scheme, have the following advantages compared to existing technologies:

[0083] First, this invention prepares a sound-absorbing, heat-insulating, and decorative composite through-hole sandwich aluminum plate by modifying and composite molding high-performance functional materials. All composite processes are cold working processes, with low requirements for production equipment and conditions, and controllable material and processing costs, giving it advantages in production and promotion.

[0084] Secondly, this invention integrates the sound absorption, heat insulation, and decorative functions of sandwich aluminum panels through high-performance functional material composites, effectively simplifying the complex construction process of traditional single-function layered construction. By connecting aluminum panels or corner brackets, the installation and connection process is simplified, significantly improving construction efficiency and yielding good economic and engineering benefits.

[0085] Meanwhile, the sound-absorbing, heat-insulating, and decorative integrated composite perforated sandwich aluminum plate of the present invention reduces the use of sound-absorbing cotton compared to the conventional perforated aluminum plate + sound-absorbing fiber cotton sound-absorbing structure. It has better sound absorption effect and a wider sound absorption range than the conventional perforated aluminum plate + sound-absorbing non-woven fabric structure. Moreover, the insulation board and thickness can be customized according to the engineering insulation requirements.

[0086] In addition, the sound-absorbing, heat-insulating and decorative integrated composite through-hole sandwich aluminum panel of the present invention does not use mineral fiber cotton material, making construction more user-friendly. The three-dimensional micro-punching process avoids environmental pollution caused by the weathering and dissipation of filling materials. The sound-absorbing performance of the aluminum panel itself will not deteriorate significantly due to moisture or material aging, making its performance more stable and durable. Furthermore, the aluminum alloy material can be completely recycled and reused, which is in line with the concept of green environmental protection.

[0087] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A composite perforated sandwich aluminum plate integrating sound absorption, heat insulation, and decoration, characterized in that, This includes three-dimensional micro-perforated sound-absorbing aluminum panels, composite fiber sound-absorbing non-woven fabrics, honeycomb aluminum sandwich panels, thermal insulation boards, and embossed aluminum foil panels. The three-dimensional micro-perforated sound-absorbing aluminum plate has a plurality of recessed first conical punches and second conical punches distributed on both the first and second surfaces. The first conical punches and second conical punches are three-dimensional inverted cones, forming a first triangular cone punch and a second triangular cone punch, respectively. The first conical punches on the first surface and the second conical punches on the second surface are respectively provided correspondingly, and the first conical punches and the second conical punches penetrate each other. An elliptical through hole is formed at the middle of the plate thickness, and the diameter of the elliptical through hole accounts for 25% of the total length between the first triangular pyramid punch hole and the second triangular pyramid punch hole; The height of the triangular pyramids of the first and second conical punches is 70% of the total thickness of the three-dimensional micro-perforated sound-absorbing aluminum plate, and the total area of ​​the triangular triangles on the bottom surface of the three-dimensional triangular punches accounts for 70% of the area of ​​the three-dimensional micro-perforated sound-absorbing aluminum plate. The three-dimensional micro-perforated sound-absorbing aluminum plate body is formed into a front plate and a rear plate by two bending. The cavity formed between the front plate and the rear plate is used to install composite fiber sound-absorbing non-woven fabric, honeycomb aluminum interlayer, thermal insulation board, and embossed aluminum foil. At the same time, the inflection points of the two folds are used to fix the composite fiber sound-absorbing non-woven fabric, honeycomb aluminum interlayer, thermal insulation board, and embossed aluminum foil placed in the cavity. The width of the cavity formed between the three-dimensional micro-perforated sound-absorbing aluminum plates is 85mm-95mm. The composite fiber sound-absorbing non-woven fabric is located in the cavity and is set on the inner side of the vertical panel of the three-dimensional micro-perforated sound-absorbing aluminum plate. The cavity is filled with honeycomb aluminum interlayer, thermal insulation board, and embossed aluminum foil in sequence from the inside to the outside. The composite fiber sound-absorbing non-woven fabric is a composite fiber non-woven fabric of glass fiber and wood fiber with an elongation of 3%.

2. The sound-absorbing, heat-insulating, and decorative integrated composite perforated sandwich aluminum plate according to claim 1, characterized in that, The total area of ​​the through holes accounts for 20% to 30% of the area of ​​the three-dimensional micro-perforated sound-absorbing aluminum plate.

3. The sound-absorbing, heat-insulating, and decorative integrated composite through-hole sandwich aluminum plate according to claim 1, characterized in that, The three-dimensional micro-perforated sound-absorbing aluminum plate is coated with a colored coating.

4. The sound-absorbing, heat-insulating, and decorative integrated composite perforated sandwich aluminum plate according to claim 1, characterized in that, The thermal insulation board is glued to one side with embossed aluminum foil and then filled into the cavity formed by the three-dimensional micro-perforated sound-absorbing aluminum fold. The side of the thermal insulation board without aluminum foil faces the honeycomb aluminum interlayer.

5. A method for manufacturing the integrated sound-absorbing, heat-insulating, and decorative perforated sandwich aluminum plate as described in claim 1, characterized in that, The manufacturing method includes the following steps: (1) A three-dimensional micro-perforated sound-absorbing aluminum plate is prepared by double-sided punching of aluminum alloy plate using a mold hydraulic punching method; the first and second surfaces of the three-dimensional micro-perforated sound-absorbing aluminum plate are respectively distributed with a number of recessed first conical punches and second conical punches. The first conical punches and second conical punches are three-dimensional inverted cones. The first conical punches on the first surface and the second conical punches on the second surface are respectively set to correspond to each other. The first conical punches and the second conical punches penetrate each other to form an elliptical through hole at the middle position of the plate thickness. The diameter of the elliptical through hole accounts for 25% of the total length between the first triangular cone punches and the second triangular cone punches. (2) Cut the three-dimensional micro-hole sound-absorbing aluminum plate according to the size of the sandwich panel. After cutting the rectangles at the four corners, bend the plate and cut the corners at a 45° angle to make the plate tightly fit the edges. (3) Use aluminum alloy cold working equipment to bend the cut three-dimensional micro-perforated sound-absorbing aluminum plate. Bend each side twice to form a front plate and a back plate. The cavity formed between the front plate and the back plate is used to install composite fiber sound-absorbing non-woven fabric, honeycomb aluminum interlayer, thermal insulation cotton board and embossed aluminum foil board. At the same time, the inflection point of the two folds is used to fix the composite fiber sound-absorbing non-woven fabric, honeycomb aluminum interlayer, thermal insulation cotton board and embossed aluminum foil board placed in the cavity. (4) According to the decoration design requirements, the three-dimensional micro-perforated sound-absorbing aluminum plate is surface treated by electrostatic spraying or oxidation coloring process, and the material is composited after the coating is dried and fixed. (5) Adhesive-backed composite fiber sound-absorbing nonwoven fabric is pasted onto the inner side of the vertical panel of the three-dimensional micro-perforated sound-absorbing aluminum plate, and heated with an electric iron to improve the bonding ability of the hot melt resin adhesive. (6) After fully unfolding the honeycomb aluminum sandwich, cut it to a size slightly smaller than the design size of the sandwich panel, fill it into the cavity of the three-dimensional micro-perforated sound-absorbing aluminum plate square box, place it on the back of the composite fiber sound-absorbing non-woven fabric, and glue the edge strips formed by cutting the honeycomb aluminum to the inner side wall of the cavity of the three-dimensional micro-perforated sound-absorbing aluminum plate square box with structural adhesive. (7) The insulation board is bonded to the aluminum foil board with structural adhesive on one side and embossed. Then it is inserted into the cavity of the three-dimensional micro-perforated sound-absorbing aluminum plate square box to fill it. The side of the aluminum foil without embossing faces the three-dimensional micro-perforated sound-absorbing aluminum plate and forms a sound-absorbing, heat-insulating and decorative integrated composite perforated sandwich aluminum plate with the honeycomb aluminum interlayer, composite fiber sound-absorbing non-woven fabric and three-dimensional micro-perforated sound-absorbing aluminum plate.

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