A method for manufacturing a class a composite thermal and sound insulation board, and a floor structure system

Abstract

The application relates to a manufacturing method of a class-A composite heat-preservation and sound-insulation board and a floor structure system. The application is realized through the following technical scheme: B1-grade polystyrene boards are cut into standard boards with a set size and at least one wave-shaped side; inorganic slurry is injected into the standard boards in a mold; cement glass fiber mesh is pressed and attached to one side of the wave-shaped surface of the standard board; and the mold is placed in a curing room for curing and shaping. The application can improve the sound insulation effect of the floor and enhance the fireproof performance.

Description

Technical Field

[0001] This invention relates to the field of sound insulation panels, and in particular to a method for manufacturing a Class A composite thermal insulation and sound insulation panel, and a floor slab structure system. Background Technology

[0002] The descriptions in this section are provided only as background information relating to this disclosure and do not constitute prior art.

[0003] In related technologies, building sound insulation is divided into airborne sound insulation and impact sound insulation. Continuous, thick concrete floor slabs are effective at insulating airborne sound, but their effectiveness at insulating impact sound is very poor. As people's living standards improve, their demands for the quality of their living environment are increasing, which is also one of the important indicators for evaluating green buildings. Market research shows that when the impact sound pressure level of the floor slab is below 65dB, the satisfaction rate can reach over 65%.

[0004] The newly revised GB50118-2022 "Standard for Sound Insulation Design of Civil Buildings" has set higher requirements for the single-value evaluation of impact sound insulation of the floor slabs separating bedrooms and living rooms, and these requirements have become mandatory. Meanwhile, various local standards have also been successively issued. Highly efficient floating sound insulation floor slabs will become standard in newly constructed civil buildings.

[0005] Currently, floating sound insulation floor slabs on the market are mainly divided into three types: organic boards, inorganic fiberboards, and lightweight mortar. Organic boards, primarily polystyrene boards, are the most widely used sound insulation products on the market. These products offer good thermal and sound insulation, but have poor fire resistance, low strength, and require a high-quality protective layer. Inorganic fiberboards offer good fire resistance and sound insulation, but their extremely low strength necessitates an even higher level of protection. Lightweight mortars have good strength and fire resistance, but poor thermal and sound insulation, and require a long construction period for wet installations. Summary of the Invention

[0006] The purpose of this invention is to provide a method for manufacturing a Class A composite thermal insulation and sound insulation board and a sound insulation floor structure system, which can improve the sound insulation effect of the floor and enhance its fire resistance.

[0007] This invention is achieved through the following technical solution: a method for manufacturing a Class A composite thermal insulation and soundproofing board, characterized in that:

[0008] Cut B1 grade polystyrene boards into standard boards of specified dimensions, with at least one side having a corrugated shape;

[0009] Inorganic slurry is injected into the mold onto a standard plate;

[0010] Cement fiberglass mesh is pressed onto one side of the corrugated surface of the standard board;

[0011] The mold is placed in a curing room to cure and set.

[0012] This manufacturing method modifies B1-grade polystyrene boards by injecting inorganic slurry. This retains the thermal insulation and soundproofing properties of polystyrene while adding the characteristics of inorganic materials, thus improving fire resistance and increasing strength, achieving Class A protection performance. Furthermore, the formed board has a corrugated surface, increasing the sound wave reflection surface and further enhancing sound insulation. Cement fiberglass mesh is also incorporated. The cement fiberglass mesh increases the tensile strength of the board, and its porosity allows the inorganic slurry to penetrate, increasing the overall strength of the composite thermal and sound insulation board. Moreover, when cement is poured onto the composite thermal and sound insulation board later, the upper layer of cement further penetrates into the cement fiberglass mesh, further increasing the overall strength of the floor slab.

[0013] Furthermore, at least one side of the cement fiberglass mesh protrudes beyond the outer edge of the standard board. This not only facilitates the splicing of composite thermal insulation and soundproofing boards, but also covers the seams when adjacent insulation boards are joined, thereby improving the splicing effect.

[0014] Preferably, the inorganic slurry is prepared using the following weight ratios: 700-1000 parts of P.O42.5 cement, 0-300 parts of high-alumina cement, 10-100 parts of acrylic emulsion, 40 parts of hydrogen peroxide foaming agent, 0.2 parts of polycarboxylate superplasticizer, 0.1 parts of tartaric acid retarder, 2 parts of magnesium aluminum silicate thixotropic agent, 1-1.5 parts of HEMC thickener, 2 parts of calcium formate early strength agent, and 120-200 parts of water.

[0015] This invention also provides a Class A composite thermal insulation floating sound insulation floor slab structure system, characterized in that: it includes a horizontal layer, which comprises, from bottom to top, a concrete floor slab structure layer, a first microbubble sound insulation bonding mortar layer, a Class A composite thermal insulation and sound insulation layer, a fine stone concrete protective layer, and a finishing layer, wherein the Class A composite thermal insulation and sound insulation layer is made by splicing together thermal insulation and sound insulation boards prepared by the aforementioned method for manufacturing Class A composite thermal insulation and sound insulation boards.

[0016] The Class A composite thermal insulation floating soundproof floor slab structure system uses Class A materials, which have good fire resistance; it features layered insulation, providing excellent thermal and sound insulation; it has high product strength and requires no special protective treatment; and it can be laid using a thin method, resulting in a short construction period.

[0017] Furthermore, it also includes a vertical layer, which includes a vertical wall, a second microbubble sound insulation bonding mortar layer and a vertical sound insulation sheet arranged sequentially from the inside of the vertical wall to the outside, and a skirting board arranged on the second microbubble sound insulation bonding mortar layer and the vertical sound insulation sheet and connected to the vertical wall, wherein the vertical sound insulation sheet is connected to the horizontal shelf.

[0018] Preferably, the microbubble sound-insulating bonding mortar layer is prepared and cast using the following weight ratios: 600-700 parts ordinary Portland cement, 70 parts Class I fly ash, 30 parts latex powder, 4 parts 8000 mPa·s cellulose ether, 0.5 parts polycarboxylate superplasticizer, 0.3 parts fatty alcohol polyoxyethylene ether air-entraining agent, 5 parts Seal80 water-repellent agent, 2 parts T500 starch ether, 4 parts calcium formate, 2 parts magnesium aluminum silicate, and 100-200 parts 100-mesh vitrified microspheres.

[0019] The addition of this microbubble sound-insulating bonding mortar results in a lightweight and high-strength material that exhibits excellent adhesion to concrete floor slabs and Class A composite thermal insulation and sound insulation boards, while also providing some thermal insulation and sound insulation effects. As a bonding layer, the microbubble sound-insulating bonding mortar effectively adheres and fixes the Class A composite thermal insulation and sound insulation boards, preventing displacement of the sound insulation boards and dust generation from the cast-in-place concrete floor slab. Simultaneously, as a transition layer, it divides the floating sound insulation floor slab into multiple layers, thereby increasing the overall sound insulation effect of the system.

[0020] Preferably, the thickness of the first microbubble sound insulation bonding mortar layer is 3-5mm, the thickness of the fine stone concrete protective layer is 2-4cm, and the thickness of the Class A composite thermal insulation and sound insulation layer is 2-3cm.

[0021] Compared with previous technologies, the beneficial effects of the present invention are as follows:

[0022] 1. The manufacturing method of this invention involves modifying a B1-grade polystyrene board by injecting an inorganic slurry. This not only retains the thermal insulation and sound insulation effects of polystyrene board but also adds the characteristics of inorganic materials, thereby improving fire resistance and increasing strength, achieving Class A protection performance. Furthermore, the formed board has a corrugated surface with uneven texture, which increases the sound wave reflection surface and further enhances the sound insulation effect. A cement-fiberglass mesh is also incorporated. The cement-fiberglass mesh increases the tensile strength of the board, and its porosity allows the inorganic slurry to penetrate, increasing the overall strength of the composite thermal and sound insulation board. Moreover, when cement is poured onto the composite thermal and sound insulation board later, the upper layer of cement further penetrates into the cement-fiberglass mesh, further increasing the overall strength of the floor slab.

[0023] 2. The Class A composite thermal insulation floating soundproof floor slab structure system of this invention uses Class A materials, which have good fire resistance; it has layered barrier, which has good thermal insulation and sound insulation effects; the product has high strength and does not require special protective treatment; it is laid in a thin method, which has a short construction period. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of the composite thermal insulation and sound insulation board after molding, as shown in the embodiment.

[0025] Figure 2 This is a bottom view of the molded composite thermal insulation and sound insulation board in the embodiment.

[0026] Figure 3 This is a cross-sectional view of the molded composite thermal insulation and sound insulation board in the embodiment;

[0027] Figure 4 This is a structural schematic diagram of a Class A composite thermal insulation floating soundproof floor slab system as shown in the embodiment.

[0028] Labeling Explanation: 1. Grade A composite thermal insulation and sound insulation board; 11. Grade B1 polystyrene board; 12. Cement slurry layer; 13. Cement fiberglass mesh; 2. Horizontal layer; 21. Concrete floor slab structural layer; 22. First micro-foam sound insulation bonding mortar layer; 23. Grade A composite thermal insulation and sound insulation layer; 24. Fine stone concrete protective layer; 25. Finishing layer; 3. Vertical layer; 31. Vertical wall; 32. Second micro-foam sound insulation bonding mortar layer; 33. Vertical sound insulation sheet; 34. Skirting board. Detailed Implementation

[0029] The present invention will now be described in detail with reference to the accompanying drawings:

[0030] Example 1:

[0031] This embodiment relates to a method for manufacturing a Class A composite thermal insulation and soundproofing board, including the following steps:

[0032] Cut B1 grade polystyrene board 11 into standard boards of a specified size, with at least one side having a corrugated shape;

[0033] Inorganic slurry is injected into the mold onto a standard plate;

[0034] 13 Cement fiberglass mesh is pressed onto one side of the corrugated surface of the standard board;

[0035] The mold is placed in a curing room to cure and set.

[0036] Furthermore, the cement fiberglass mesh protrudes beyond the outer edge of the standard plate on two adjacent sides. The formed plate is as follows: Figure 1-3 As shown, this not only facilitates the splicing of composite thermal insulation and sound insulation boards, but also covers the seams when adjacent insulation boards are joined, thereby improving the splicing effect.

[0037] This manufacturing method modifies B1-grade polystyrene boards by injecting inorganic slurry. This retains the thermal insulation and soundproofing properties of polystyrene while adding the characteristics of inorganic materials, thus improving fire resistance and increasing strength, achieving Class A protection performance. Furthermore, the formed board has a corrugated surface, increasing the sound wave reflection surface and further enhancing sound insulation. Cement fiberglass mesh is also incorporated. The cement fiberglass mesh increases the tensile strength of the board, and its porosity allows the inorganic slurry to penetrate, increasing the overall strength of the composite thermal and sound insulation board. Moreover, when cement is poured onto the composite thermal and sound insulation board later, the upper layer of cement further penetrates into the cement fiberglass mesh, further increasing the overall strength of the floor slab.

[0038] The inorganic slurry in this embodiment was prepared using the weight ratios shown in the table below:

[0039] Material Cement 1 Cement 2 lotion foaming agent Water reducing agent Retarder thixotropic agents Thickener Early strength agent water model P.O42.5 High-alumina cement acrylic acid hydrogen peroxide Polycarboxylic acid tartaric acid Magnesium aluminum silicate HEMC Calcium formate tap water Dosage 700 300 100 40 0.2 0.1 2 1 2 120

[0040] The molded Class A composite thermal insulation and sound insulation board 1 is as follows Figure 1-3 As shown, B1 grade polystyrene board 11 serves as the main body, with a cement slurry layer 12 wrapped around its outer periphery, a corrugated surface formed on its upper surface, and a cement fiberglass mesh 13 connected to the corrugated surface.

[0041] Example 2:

[0042] The difference between this embodiment and Embodiment 1 is that the inorganic slurry is prepared using the weight ratios shown in the table below:

[0043] Material Cement 1 Cement 2 lotion foaming agent Water reducing agent Retarder thixotropic agents Thickener Early strength agent water model P.O42.5 High-alumina cement acrylic acid hydrogen peroxide Polycarboxylic acid tartaric acid Magnesium aluminum silicate HEMC Calcium formate tap water Dosage 850 150 50 40 0.2 0.1 2 1.2 2 170

[0044] Example 3

[0045] The difference between this embodiment and Embodiment 1 is that the inorganic slurry is prepared using the weight ratios shown in the table below:

[0046] Material Cement 1 Cement 2 lotion foaming agent Water reducing agent Retarder thixotropic agents Thickener Early strength agent water model P.O42.5 High-alumina cement acrylic acid hydrogen peroxide Polycarboxylic acid tartaric acid Magnesium aluminum silicate HEMC Calcium formate tap water Dosage 1000 0 10 40 0.2 0.1 2 1.5 2 210

[0047] The performance indicators of the Class A composite thermal insulation and sound insulation boards prepared by the methods of Examples 1 to 3 are shown in the table below:

[0048]

[0049] All three Class A composite thermal and sound insulation panels exhibit good physical strength, A2-level fire resistance, good thermal insulation performance, and environmentally friendly physical indicators. Among them, Example 1 has the best overall performance and is suitable for locations with high standards.

[0050] Example 4:

[0051] like Figure 4As shown, an A-grade composite thermal insulation floating sound insulation floor slab structure system is characterized by: including a horizontal layer 2, wherein the horizontal layer includes, from bottom to top, a concrete floor slab structure layer 21, a first microbubble sound insulation bonding mortar layer 22, an A-grade composite thermal insulation and sound insulation layer 23, a fine stone concrete protective layer 24, and a finishing layer 25, wherein the A-grade composite thermal insulation and sound insulation layer 23 is made by splicing together thermal insulation and sound insulation boards prepared by the manufacturing method of the A-grade composite thermal insulation and sound insulation board described in Example 1.

[0052] Furthermore, it also includes a vertical layer 3, which includes a vertical wall 31, a second microbubble sound insulation bonding mortar layer 32 and a vertical sound insulation sheet 33 arranged sequentially from the inside to the outside of the vertical wall 31, and a skirting board 34 disposed on the second microbubble sound insulation bonding mortar layer 32 and the vertical sound insulation sheet 33 and connected to the vertical wall. The vertical sound insulation sheet 33 is connected to the horizontal shelf.

[0053] The second microbubble sound-insulating bonding mortar layer is prepared and cast using the same surface weight ratio as the first microbubble sound-insulating bonding mortar layer. The Class A composite thermal insulation and sound insulation layer is made of the same material as the vertical sound insulation sheet.

[0054] In this embodiment, the microbubble sound-insulating bonding mortar layer is prepared and applied by troweling using the weight ratios shown in the table below:

[0055]

[0056] In this embodiment, the Class A composite thermal insulation and sound insulation board is made from inorganic slurry prepared according to the weight ratios shown in the table below:

[0057] Material Cement 1 Cement 2 lotion foaming agent Water reducing agent Retarder thixotropic agents Thickener Early strength agent water model P.O42.5 High-alumina cement acrylic acid hydrogen peroxide Polycarboxylic acid tartaric acid Magnesium aluminum silicate HEMC Calcium formate tap water Dosage 700 300 100 40 0.2 0.1 2 1 2 120

[0058] According to GB / T19889.3-2005 "Acoustics - Measurement of sound insulation of buildings and building components - Part 3: Laboratory measurement of airborne sound insulation of building components", the performance of the Class A composite thermal insulation floating sound insulation floor slab structure system was measured, and the specific performance is shown in the table below:

[0059]

[0060] This solution is an optimal combination, with high system strength and excellent thermal insulation and sound insulation effects. It can be used for all floor surface layers, and is especially suitable for building floor insulation and sound insulation places with high requirements for sound insulation and floor strength, such as high-end residential communities, high-end hotels, hospitals and other places. It is particularly suitable for floors with solid wood flooring and underfloor heating.

[0061] The construction process in this embodiment is as follows:

[0062] 1. Clean the base layer: Clean the ground and corners of the walls, removing dust, grease and other contaminants. Fill and level any pits, bumps and uneven areas.

[0063] 2. Marking lines: Draw elevation lines around the corners of the wall.

[0064] 3. Applying vertical sound insulation sheets: Mix the micro-foam sound insulation bonding mortar according to the specified water-cement ratio, and lay the Class A composite thermal insulation and sound insulation board in sequence according to the thin-set tile construction process. The upper edge of the vertical sound insulation sheet should be flush with the elevation line, and the thickness of the micro-foam sound insulation bonding mortar layer should be 3-5mm.

[0065] 4. Laying Class A composite thermal insulation and sound insulation boards: Mix micro-foam sound insulation bonding mortar according to the specified water-cement ratio, and lay Class A composite thermal insulation and sound insulation boards in sequence according to the thin-set tile construction process, with the outer cement fiberglass cloth overlapping in sequence.

[0066] 5. Pour fine aggregate concrete: Pour a 2.5cm thick concrete layer to protect the sound insulation board.

[0067] 6. Laying the finishing layer: According to the design, lay the floor tiles, wood flooring, and other finishing layers.

[0068] Example 5:

[0069] This embodiment relates to a Class A composite thermal insulation floating sound insulation floor slab structure system, characterized in that: it includes a horizontal layer 2, which includes, from bottom to top, a concrete floor slab structure layer 21, a first microbubble sound insulation bonding mortar layer 22, a Class A composite thermal insulation and sound insulation layer 23, a fine stone concrete protective layer 24, and a finishing layer 25. The Class A composite thermal insulation and sound insulation layer 23 is made by splicing together thermal insulation and sound insulation boards prepared by the manufacturing method of Class A composite thermal insulation and sound insulation board described in Embodiment 2.

[0070] Furthermore, it also includes a vertical layer 3, which includes a vertical wall 31, a second microbubble sound insulation bonding mortar layer 32 and a vertical sound insulation sheet 33 arranged sequentially from the inside to the outside of the vertical wall 31, and a skirting board 34 disposed on the second microbubble sound insulation bonding mortar layer 32 and the vertical sound insulation sheet 33 and connected to the vertical wall. The vertical sound insulation sheet 33 is connected to the horizontal shelf.

[0071] In this embodiment, the microbubble sound-insulating bonding mortar layer is prepared and cast using the weight ratios shown in the table below:

[0072]

[0073] In this embodiment, the Class A composite thermal insulation and sound insulation board is made from inorganic slurry prepared according to the weight ratios shown in the table below:

[0074] Material Cement 1 Cement 2 lotion foaming agent Water reducing agent Retarder thixotropic agents Thickener Early strength agent water model P.O42.5 High-alumina cement acrylic acid hydrogen peroxide Polycarboxylic acid tartaric acid Magnesium aluminum silicate HEMC Calcium formate tap water Dosage 850 150 50 40 0.2 0.1 2 1.2 2 170

[0075] According to GB / T19889.3-2005 "Acoustics - Measurement of sound insulation of buildings and building components - Part 3: Laboratory measurement of airborne sound insulation of building components", the performance of the Class A composite thermal insulation floating sound insulation floor slab structure system was measured, and the specific performance is shown in the table below:

[0076]

[0077] This solution is a mid-range combination, with good system strength and sound insulation. It can be used for all floor surface layers and is suitable for sound insulation and thermal insulation of ordinary civil buildings, such as residential communities, commercial hotels, office buildings, schools, and other places. The construction steps for Example 5 are the same as those for Example 4.

[0078] Example 6:

[0079] A Class A composite thermal insulation floating soundproof floor slab structure system, characterized in that: it includes a horizontal layer 2, which comprises, from bottom to top, a concrete floor slab structure layer 21, a first microbubble sound insulation bonding mortar layer 22, a Class A composite thermal insulation and sound insulation layer 23, a fine stone concrete protective layer 24, and a finishing layer 25, wherein the Class A composite thermal insulation and sound insulation layer 23 is made by splicing together thermal insulation and sound insulation boards prepared by the manufacturing method of the Class A composite thermal insulation and sound insulation board described in Example 3.

[0080] Furthermore, it also includes a vertical layer 3, which includes a vertical wall 31, a second microbubble sound insulation bonding mortar layer 32 and a vertical sound insulation sheet 33 arranged sequentially from the inside to the outside of the vertical wall 31, and a skirting board 34 disposed on the second microbubble sound insulation bonding mortar layer 32 and the vertical sound insulation sheet 33 and connected to the vertical wall. The vertical sound insulation sheet 33 is connected to the horizontal shelf.

[0081] In this embodiment, the microbubble sound-insulating bonding mortar layer is prepared and cast using the weight ratios shown in the table below:

[0082]

[0083] In this embodiment, the Class A composite thermal insulation and sound insulation board is made from inorganic slurry prepared according to the weight ratios shown in the table below:

[0084] Material Cement 1 Cement 2 lotion foaming agent Water reducing agent Retarder thixotropic agents Thickener Early strength agent water model P.O42.5 High-alumina cement acrylic acid hydrogen peroxide Polycarboxylic acid tartaric acid Magnesium aluminum silicate HEMC Calcium formate tap water Dosage 1000 0 10 40 0.2 0.1 2 1.5 2 210

[0085] According to GB / T19889.3-2005 "Acoustics - Measurement of sound insulation of buildings and building components - Part 3: Laboratory measurement of airborne sound insulation of building components", the performance of the Class A composite thermal insulation floating sound insulation floor slab structure system was measured, and the specific performance is shown in the table below:

[0086]

[0087]

[0088] This solution is a low-end combination, with moderate system strength and thermal and sound insulation, suitable for places where the requirements for thermal and sound insulation are not very high, and for floors with hard materials such as ceramic tiles as the finishing layer. The construction steps for Example 6 are the same as those for Example 4.

[0089] Although the present invention has been illustrated and described through specific embodiments and alternative methods, it should be understood that various changes and modifications may be made without departing from the spirit and scope of the invention. Therefore, it should be understood that the present invention is not limited in any sense except by the appended claims and their equivalents.

Claims

1. A method for manufacturing a Class A composite thermal insulation and soundproofing board, characterized in that: Cut B1 grade polystyrene boards into standard boards of specified dimensions, with at least one side having a corrugated shape; Inorganic slurry is injected into the mold onto a standard plate; Cement fiberglass mesh is pressed onto one side of the corrugated surface of the standard board; Place the mold in a curing room to cure and set its shape; At least one side of the cement fiberglass mesh protrudes from the outer edge of the standard plate; The inorganic slurry is prepared using the following weight ratios: 700-1000 parts of P.O42.5 cement, 0-300 parts of high-alumina cement, 10-100 parts of acrylic emulsion, 40 parts of hydrogen peroxide foaming agent, 0.2 parts of polycarboxylate superplasticizer, 0.1 parts of tartaric acid retarder, 2 parts of magnesium aluminum silicate thixotropic agent, 1-1.5 parts of HEMC thickener, 2 parts of calcium formate early strength agent, and 120-200 parts of water.

2. A Class A composite thermal insulation floating soundproof floor slab structure system, characterized in that: The system includes a horizontal layer, which comprises, from bottom to top, a concrete floor slab structural layer, a first microbubble sound insulation bonding mortar layer, a Class A composite thermal insulation and sound insulation layer, a fine stone concrete protective layer, and a finishing layer. The Class A composite thermal insulation and sound insulation layer is made by splicing together thermal insulation and sound insulation boards prepared by the manufacturing method of the Class A composite thermal insulation and sound insulation board as described in claim 1. The microbubble sound insulation bonding mortar layer is prepared and cast using the following weight ratios: 600-700 parts ordinary Portland cement, 70 parts Class I fly ash, 30 parts latex powder, 4 parts 8000 MPa·s cellulose ether, 0.5 parts polycarboxylate superplasticizer, 0.3 parts fatty alcohol polyoxyethylene ether air-entraining agent, 5 parts Seal80 water-repellent agent, 2 parts T500 starch ether, 4 parts calcium formate, 2 parts magnesium aluminum silicate, and 100-200 parts 100-mesh vitrified microspheres.

3. The Class A composite thermal insulation floating soundproof floor slab structure system according to claim 2, characterized in that: It also includes a vertical layer, which includes a vertical wall, a second microbubble sound insulation bonding mortar layer and a vertical sound insulation sheet arranged sequentially from the inside of the vertical wall to the outside, and a skirting board arranged on the second microbubble sound insulation bonding mortar layer and the vertical sound insulation sheet and connected to the vertical wall. The vertical sound insulation sheet is connected to the horizontal shelf.

4. The Class A composite thermal insulation floating soundproof floor slab structure system according to claim 2, characterized in that: The thickness of the first microbubble sound insulation bonding mortar layer is 3-5mm, the thickness of the fine stone concrete protective layer is 2-4cm, and the thickness of the Class A composite thermal insulation and sound insulation layer is 2-3cm.

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