Sound-absorbing structure composite board based on perforated hollow ceramsite board and manufacturing method thereof

Abstract

The application discloses a sound-absorbing structure composite board based on a perforated hollow ceramsite plate and a manufacturing method thereof, and relates to the technical field of sound-absorbing boards. The sound-absorbing structure composite board is composed of no less than two sound-absorbing material boards, at least one of which is a perforated hollow ceramsite plate, and the perforated hollow ceramsite plate is provided with a plurality of sound-absorbing holes with different aperture sizes. The manufacturing method comprises the following steps: uniformly stirring hollow ceramsite, full-solid-waste cementitious material and water to obtain a slurry; pouring the slurry into a mold and vibrating until the slurry completely fills the mold, and then placing the slurry in a humid environment for curing, and then taking out the hollow ceramsite plate after natural drying; perforating the hollow ceramsite plate to obtain a perforated hollow ceramsite plate; selecting a sound-absorbing material to manufacture a sound-absorbing material board, and compositing the perforated hollow ceramsite plate and the sound-absorbing material board to obtain the sound-absorbing structure composite board. The sound-absorbing holes with different aperture sizes are staggered on the hollow ceramsite plate, so that the sound-absorbing board can effectively absorb sound waves with multiple frequencies at the same time.

Description

Technical Field

[0001] This invention relates to the field of sound-absorbing panel technology, and in particular to a sound-absorbing structural composite panel based on perforated hollow ceramsite panels and its manufacturing method. Background Technology

[0002] Noise pollution, along with water pollution, air pollution, and solid waste pollution, are major environmental problems worldwide. To reduce the adverse effects of noise pollution on people's lives, existing technologies employ sound-absorbing materials that can effectively shield sound energy and reduce sound radiation to create sound-absorbing panels. For example, the existing technology CN202008830U provides a composite sound-absorbing panel, which includes upper and lower panels and sound-absorbing material between them. Both upper and lower panels are perforated panels, connected by a keel. The sound-absorbing material fills the cavity formed by the upper and lower panels and the keel. This sound-absorbing material is a porous fiber material layer, which is covered with fiberglass cloth. This sound-absorbing panel has a simple structure and can play a major role in large, medium, and small sound-absorbing equipment according to size requirements. It can also be installed indoors to significantly reduce mid- and high-frequency noise. It has good adaptability, strong durability, good sound absorption performance, a sound absorption coefficient greater than 0.98, and is easy to manufacture, transport, assemble, and install on-site. However, sound-absorbing panels with a fixed aperture may have good performance in absorbing sound waves of a specific frequency, but are less effective in absorbing sound waves of other frequencies. Summary of the Invention

[0003] The objective of this invention is to provide a sound-absorbing composite panel based on perforated hollow ceramic particle boards, as sound-absorbing panels with a fixed pore size are less effective at absorbing sound waves outside a specific frequency range.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: a sound-absorbing structural composite panel based on a perforated hollow ceramsite board, wherein the sound-absorbing structural composite panel is composed of at least two sound-absorbing material boards, wherein at least one of them is a perforated hollow ceramsite board, the sound-absorbing material board includes a board surface opposite to the board surface in the thickness direction and an end face surrounding the board surface, and the perforated hollow ceramsite board is provided with a plurality of sound-absorbing holes of different pore sizes.

[0005] By adopting the aforementioned technical solution, the present invention has the following advantages: Compared with other sound-absorbing materials, ceramsite is environmentally friendly, easy to bond and fix, and has high fire resistance, strength and moisture resistance. Ceramsite boards made of ceramsite have a long service life. By perforating the surface of the hollow ceramsite board, a perforated hollow ceramsite board with multiple sound-absorbing holes of different sizes is obtained. The sound-absorbing holes of different sizes can absorb different frequencies of sound, thereby expanding the sound absorption range of the sound-absorbing board, providing comprehensive acoustic control and improving the overall sound absorption performance.

[0006] Furthermore, the sound-absorbing holes are obtained by drilling holes perpendicular to the surface of the plate using a drilling machine. The depth of the sound-absorbing holes accounts for 80% to 90% of the total thickness of the hollow ceramsite plate in the direction of the holes, and the opening area of ​​the sound-absorbing holes on the hollow ceramsite plate accounts for 80% to 90% of the total area of ​​the hollow ceramsite plate.

[0007] Using the aforementioned technical solution, the opening area of ​​the sound-absorbing holes is relatively large, occupying most of the surface of the hollow ceramic particle board, which helps to effectively capture and absorb sound waves.

[0008] Furthermore, the pore size of the sound-absorbing holes is between 20mm and 120mm, and the mesh size of the ceramic particles in the perforated hollow ceramic particle board is between 20 mesh and 40 mesh.

[0009] Using the aforementioned technical solution, the sound-absorbing holes have a large aperture range, which can effectively absorb sound waves in various frequency ranges. Smaller holes are suitable for absorbing high-frequency sounds, while larger holes are more suitable for low-frequency sounds, providing a wide frequency absorption range and enabling the sound-absorbing panel to have a good absorption effect on various sounds.

[0010] Furthermore, the perforated hollow ceramsite board includes an adjacent base layer, the base layer comprising ceramsite of at least two mesh sizes; or, the ceramsite in the perforated hollow ceramsite board is composed of a mixture of ceramsite of at least two mesh sizes.

[0011] By adopting the aforementioned technical solution, ceramic particles of different mesh sizes are mixed together or base layers of different mesh sizes are arranged adjacently, enabling the sound-absorbing panel to effectively absorb sound waves in multiple frequency ranges. Low-mesh ceramic particles are usually used to absorb low-frequency sounds, while high-mesh ceramic particles are used to absorb high-frequency sounds, thereby providing a wide range of acoustic response.

[0012] Furthermore, the perforated hollow ceramsite board includes a first base layer and a second base layer arranged adjacent to each other. The pore diameter of the sound-absorbing holes in the first base layer is between 20mm and 60mm, and the pore diameter of the sound-absorbing holes in the second base layer is between 80mm and 120mm.

[0013] Using the aforementioned technical solution, since the sound-absorbing holes on the first and second base layers have different aperture ranges, the sound-absorbing panel can effectively absorb sound waves in multiple frequency ranges. The smaller aperture on the first base layer is usually used to absorb high-frequency sounds, while the larger aperture on the second base layer is used to absorb low-frequency sounds.

[0014] To manufacture the aforementioned sound-absorbing composite panel, the present invention adopts the following technical solution: a method for manufacturing a sound-absorbing composite panel based on perforated hollow ceramsite board, comprising the following steps:

[0015] S1. Hollow ceramsite, solid waste cementitious material and water are mixed evenly to obtain slurry;

[0016] S2. Pour the slurry into the mold and vibrate the mold until the slurry completely fills the mold. Place the completely filled mold in a humid environment for curing. After curing, remove the molded product from the mold and let it dry naturally to obtain a hollow ceramsite board.

[0017] S3. Use a drilling machine with preset perforation size, depth and distribution to drill holes in the hollow ceramsite board to obtain a perforated hollow ceramsite board.

[0018] S4. Select sound-absorbing materials to make a sound-absorbing material board, and combine the perforated hollow ceramic particle board with the sound-absorbing material board to obtain a sound-absorbing composite board.

[0019] By adopting the aforementioned technical solution, the present invention has the following advantages: the manufacturing process of the composite board is relatively simple, requiring no complex processes and equipment, and production can be completed at a low cost. Furthermore, perforations of different sizes, depths, and distributions can be designed according to the application scenario to meet specific sound absorption requirements and achieve the expected sound absorption effect.

[0020] Furthermore, S1 includes the following steps:

[0021] S11. Select the mesh size of the hollow ceramsite and obtain the required amount of hollow ceramsite, total solid waste gel material, and water.

[0022] S12. Based on the amount of hollow ceramsite, the amount of solid waste gel material, and the amount of water, the hollow ceramsite, the solid waste gel material, and the water are mixed to obtain a mixture;

[0023] S13. The mixture is stirred evenly to obtain a slurry.

[0024] By adopting the aforementioned technical solution, selecting an appropriate mesh size of hollow ceramsite based on the designed sound-absorbing composite panel structure, and determining the amounts of hollow ceramsite, solid waste gel material, and water, the material ratio can be precisely controlled, ensuring the consistency of the final composite panel. Since the amount of material can be adjusted as needed, material waste can be minimized, and material utilization rate improved. Stirring the mixture ensures that the hollow ceramsite, solid waste gel material, and water are thoroughly and evenly mixed, thus guaranteeing the consistency and stability of the final slurry quality. These steps ensure the controllability of the slurry production process, contributing to the production of ideal sound-absorbing composite panels, improving production efficiency, reducing scrap rates, and lowering production costs.

[0025] Furthermore, S2 includes the following steps:

[0026] S21. Pour the slurry into the mold, vibrate the mold to expel the gas and make the slurry completely fill the mold;

[0027] S22. Seal the mold after it is fully filled and degassed with plastic wrap and let it cure at room temperature until the chemical reaction of the slurry is complete.

[0028] S23. Demold the cured molded product to obtain the molded product. After the molded product dries naturally, hollow ceramic granule board is obtained.

[0029] By employing the aforementioned technical solution, the vibration of the mold ensures complete filling of the mold with slurry, which helps to prepare uniform and dense hollow ceramsite boards, thus ensuring the sound absorption performance of the ceramsite boards. After the mold is fully filled and vented, it is sealed with plastic wrap and cured at room temperature, which helps the slurry to fully undergo chemical reaction and hardening processes. This curing method ensures that the resulting hollow ceramsite boards have good strength and stability. Compared with high-temperature curing, room temperature curing saves energy costs and reduces production costs. After the molded product dries naturally, the hollow ceramsite boards are obtained, avoiding the use of high-temperature drying or other heating processes, further reducing energy consumption and environmental impact. This preparation process is relatively simple, does not require complex equipment or high-temperature conditions, which helps to reduce preparation costs. Furthermore, the preparation process does not require high-temperature curing, reducing energy consumption and carbon dioxide emissions, and reducing the environmental burden.

[0030] Furthermore, S3 includes the following steps:

[0031] S31. Set appropriate hole size, hole depth and hole distribution on the punching machine;

[0032] S32. Use a drilling machine with pre-set perforation size, perforation depth and perforation distribution to drill holes in the hollow ceramsite board to obtain a perforated hollow ceramsite board.

[0033] By adopting the aforementioned technical solution, the sound-absorbing structure of the hollow ceramsite board can be precisely controlled by setting the perforation size, depth, and distribution of the drilling machine according to the designed sound-absorbing composite board structure. This helps to achieve specific acoustic performance targets and ensures that the sound absorption effect meets the requirements. Using a drilling machine for perforation can ensure the uniformity and consistency of the sound-absorbing structure, avoiding problems that may be caused by uneven manual operation. The drilling machine can complete the perforation process efficiently and accurately, improving production efficiency and reducing preparation time and cost.

[0034] Furthermore, S4 includes the following steps:

[0035] S41. Select appropriate sound-absorbing materials to make sound-absorbing material boards;

[0036] S42. The sound-absorbing material board and the perforated hollow ceramic particle board are stacked and bonded together to obtain a sound-absorbing composite board.

[0037] By adopting the aforementioned technical solution, and by designing the sound-absorbing structure, selecting the appropriate sound-absorbing materials, and manufacturing them into sound-absorbing material panels, the application range of composite panels can be expanded, resulting in customized composite panels that are adaptable to various environments. By utilizing the advantages of various materials, different combinations can produce synergistic effects, increasing the multifunctionality of composite panels and further improving their sound absorption performance. Attached Figure Description

[0038] The present invention will be further described below with reference to the accompanying drawings:

[0039] Figure 1 These are schematic diagrams of the sound-absorbing composite panels in Embodiments 1, 2, and 3 of this invention.

[0040] Figure 2 This is a sound absorption coefficient-frequency characteristic curve of the sound-absorbing composite panel in Embodiment 1 of the present invention;

[0041] Figure 3 This is a sound absorption coefficient-frequency characteristic curve of the sound-absorbing composite panel in Embodiment 2 of the present invention;

[0042] Figure 4 This is a schematic diagram of the sound-absorbing composite panel in Embodiment 4 of the present invention. Detailed Implementation

[0043] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0044] The terms "first," "second," etc. (if present) in the specification and claims of this invention are used to distinguish similar objects, not to describe a specific order or sequence. Even if "second" is used before a technical feature for distinction, it does not necessarily imply the presence of "first." It should be understood that in this invention, "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion. It should be understood that in this invention, "a plurality of" refers to two or more. "And / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, X and / or Y can represent: X alone, X and Y simultaneously, and Y alone. The character " / " generally indicates that the preceding and following related objects are in an "or" relationship. "Containing X, Y, and Z," "Containing X, Y, and Z" means that all three X, Y, and Z are included; "Containing X, Y, or Z" means that one of X, Y, and Z is included; "Containing X, Y, and / or Z" means that any one, two, or three of X, Y, and Z are included.

[0045] It should be noted that the solid waste gelling material used in the following embodiments is from Shanxi Yunhong Environmental Technology Development Co., Ltd., with an initial setting time of 270 min and a final setting time of 410 min. This invention achieves high strength without adding any additives or admixtures. However, this invention is not limited to this; any admixtures and additives known to those skilled in the art can also be used. These modified solutions should all be understood to fall within the scope of protection of this invention.

[0046] This application provides a sound-absorbing structural composite panel based on a perforated hollow ceramsite board. The composite panel is composed of at least two sound-absorbing material panels, at least one of which is a perforated hollow ceramsite board. Each sound-absorbing material panel includes a surface facing each other in the thickness direction and an end face surrounding the surface. The perforated hollow ceramsite board has multiple sound-absorbing holes of different sizes. Ceramsite typically has good sound absorption performance. Whether the sound-absorbing holes of different sizes are staggered or concentrated, they can provide a broad-spectrum sound absorption effect. Different sized sound-absorbing holes can absorb sound waves of different frequencies, from low to high frequencies, providing comprehensive acoustic control. This allows the sound-absorbing structural composite panel to absorb sound waves in multiple different frequency ranges, from low to high frequencies, improving the overall comprehensiveness of its sound absorption performance.

[0047] To facilitate the easier entry and scattering of sound waves into the holes, the sound-absorbing holes are created by drilling perpendicularly to the surface of the board. The depth of these holes accounts for 80%–90% of the total thickness of the hollow ceramsite board along the drilling direction, and the opening area of ​​these holes accounts for 80%–90% of the total area of ​​the hollow ceramsite board. This design significantly improves sound absorption efficiency. The vertically arranged, uniformly distributed holes across the entire board surface contribute to uniform sound absorption performance. The high opening area of ​​the holes, accounting for 80%–90% of the total area of ​​the hollow ceramsite board, means that the board has more sound-absorbing holes, which helps to more effectively absorb and scatter sound waves. This structure provides excellent sound absorption performance, reducing indoor or outdoor noise pollution. The large opening area of ​​the sound-absorbing holes, occupying most of the surface of the hollow ceramsite board, helps to effectively capture and absorb sound waves.

[0048] Specifically, the pore size of the sound-absorbing holes is between 20mm and 120mm, and the mesh size of the ceramsite in the perforated hollow ceramsite board is between 20 mesh and 40 mesh. The wide range of pore sizes allows for effective absorption of sound waves across various frequency ranges. Smaller pores are suitable for absorbing high-frequency sounds, while larger pores are better suited for absorbing low-frequency sounds, providing a broad frequency absorption range and enabling the sound-absorbing board to effectively absorb various types of sound. Existing technology data shows that boards with a perforation depth of 88% and a pore size of 40mm to 120mm can absorb sound waves in the 100Hz to 500Hz range with an average sound absorption coefficient >0.57, which is 3.5% to 8% higher than that of non-perforated boards; boards with a perforation depth of 88% and a pore size of 120mm can absorb sound waves in the 50Hz to 2000Hz range with a maximum sound absorption coefficient of 0.99, which is 31% higher than that of non-perforated boards; the perforated hollow ceramsite board has a ceramsite mesh size of 20 mesh to 4 mesh. Hollow ceramsite with a mesh size between 0 and 40 mesh has a certain particle size. Ceramsite with a mesh size that is too small may not have enough sound-absorbing surface area, while ceramsite with a mesh size that is too large may not have enough pore structure to capture and absorb sound waves, thus leading to a decrease in sound absorption performance. A moderate pore size can effectively capture and absorb sound waves. The relatively uniform particle size of hollow ceramsite helps to achieve uniform dispersion when mixing slurry, ensuring the uniformity of the prepared sound-absorbing material. In addition, a larger mesh size can reduce dust generation during the production process, reduce preparation costs, and improve the safety of the working environment.

[0049] Understandably, in order to absorb sound waves of different frequencies, in addition to designing sound-absorbing holes with different aperture sizes and staggered distribution on the perforated hollow ceramsite board, hollow ceramsite boards can also be made by selecting ceramsite with different mesh sizes.

[0050] In one embodiment, and in another embodiment, the perforated hollow ceramsite board includes an adjacently arranged base layer, the base layer comprising ceramsite of at least two mesh sizes;

[0051] Specifically, the perforated hollow ceramsite board includes a first base layer and a second base layer arranged adjacent to each other. The pore size of the sound-absorbing holes in the first base layer is between 20mm and 60mm, while the pore size of the sound-absorbing holes in the second base layer is between 80mm and 120mm. Because the sound-absorbing holes in the first and second base layers have different pore size ranges, the sound-absorbing board can effectively absorb sound waves in multiple frequency ranges. The smaller pore size in the first base layer is typically used to absorb high-frequency sounds, while the larger pore size in the second base layer is used to absorb low-frequency sounds.

[0052] Understandably, the ceramsite in perforated hollow ceramsite panels can also be composed of a mixture of ceramsite with at least two different mesh sizes. Mixing ceramsite with different mesh sizes together or placing base layers of different mesh sizes adjacent to each other allows the sound-absorbing panel to effectively absorb sound waves across multiple frequency ranges. Lower mesh size ceramsite is typically used to absorb low-frequency sounds, while higher mesh size ceramsite is used to absorb high-frequency sounds, thus providing a wide range of acoustic response.

[0053] Specifically, in order to manufacture the aforementioned sound-absorbing composite panel, this embodiment provides a method for manufacturing a sound-absorbing composite panel based on perforated hollow ceramsite boards. The manufacturing method includes the following steps:

[0054] 1) Slurry preparation:

[0055] S1. Hollow ceramsite, solid waste cementitious material and water are mixed evenly to obtain slurry;

[0056] 2) Injection molding, demolding, and drying:

[0057] S2. Pour the slurry into the mold and vibrate the mold until the slurry completely fills the mold. Place the completely filled mold in a humid environment for curing. After curing, remove the molded product from the mold and let it dry naturally to obtain a hollow ceramsite board.

[0058] 3) Substrate perforation:

[0059] S3. Use a drilling machine with preset perforation size, depth and distribution to drill holes in the hollow ceramsite board to obtain a perforated hollow ceramsite board.

[0060] 4) Composite panels:

[0061] S4. Select sound-absorbing materials to make a sound-absorbing material board, and combine the perforated hollow ceramic particle board with the sound-absorbing material board to obtain a sound-absorbing composite board.

[0062] Perforated hollow ceramsite panels possess excellent sound absorption properties, effectively reducing noise and sound reflection, providing a quieter environment. They are also lighter than traditional sound-absorbing materials, reducing the overall weight of the composite sound-absorbing panel and making it easier to install and hang. Using all-solid waste cementitious materials is environmentally friendly, reducing the consumption of natural resources and effectively managing waste materials. The manufacturing process of the composite panels is relatively simple, requiring no complex processes or equipment, and can be completed at a low cost. Furthermore, perforations of different sizes, depths, and distributions can be designed according to the application scenario to meet specific sound absorption requirements and achieve the desired sound absorption effect.

[0063] Specifically, S1 includes the following steps:

[0064] S11. Select the mesh size of the hollow ceramsite and obtain the required amount of hollow ceramsite, total solid waste gel material, and water.

[0065] S12. Based on the amount of hollow ceramsite, the amount of solid waste gel material, and the amount of water, the hollow ceramsite, the solid waste gel material, and the water are mixed to obtain a mixture;

[0066] S13. The mixture is stirred evenly to obtain a slurry.

[0067] By selecting an appropriate mesh size of hollow ceramsite based on the designed sound-absorbing composite panel structure, and by determining the amounts of hollow ceramsite, solid waste gel material, and water, the material ratio can be precisely controlled, ensuring the consistency of the final composite panel. Since the amount of material can be adjusted as needed, material waste can be minimized, and material utilization rate can be improved. Stirring the mixture ensures that the hollow ceramsite, solid waste gel material, and water are thoroughly and evenly mixed, thus guaranteeing the consistency and stability of the final slurry quality. These steps ensure the controllability of the slurry production process, contributing to the production of ideal sound-absorbing composite panels, improving production efficiency, reducing scrap rates, and lowering production costs.

[0068] Specifically, S2 includes the following steps:

[0069] S21. Pour the slurry into the mold, vibrate the mold to expel the gas and make the slurry completely fill the mold;

[0070] S22. Seal the mold after it is fully filled and degassed with plastic wrap and let it cure at room temperature until the chemical reaction of the slurry is complete.

[0071] S23. Demold the cured molded product to obtain the molded product. After the molded product dries naturally, hollow ceramic granule board is obtained.

[0072] This curing method ensures that the resulting hollow ceramsite panels have good strength and stability. Compared with high-temperature curing, room-temperature curing saves energy costs and reduces production costs. After the molded products are naturally dried, the hollow ceramsite panels are obtained, which avoids the use of high-temperature drying or other heating processes, further reducing energy consumption and environmental impact. This preparation process is relatively simple and does not require complex equipment or high-temperature conditions, which helps to reduce preparation costs. Moreover, the preparation process does not require high-temperature curing, reducing energy consumption and carbon dioxide emissions, and reducing the environmental burden.

[0073] Specifically, S3 includes the following steps:

[0074] S31. Set appropriate hole size, hole depth and hole distribution on the punching machine;

[0075] S32. Use a drilling machine with pre-set perforation size, perforation depth and perforation distribution to drill holes in the hollow ceramsite board to obtain a perforated hollow ceramsite board.

[0076] By setting the perforation size, depth, and distribution of the drilling machine according to the designed sound-absorbing composite panel structure, the sound-absorbing structure of the hollow ceramsite board can be precisely controlled, which helps to achieve specific acoustic performance goals and ensures that the sound absorption effect meets the requirements. Using a drilling machine for perforation can ensure the uniformity and consistency of the sound-absorbing structure, avoiding problems that may be caused by uneven manual operation. The drilling machine can complete the perforation process efficiently and accurately, improving production efficiency and reducing preparation time and cost.

[0077] The specific S4 includes the following steps:

[0078] S41. Select appropriate sound-absorbing materials to make sound-absorbing material boards;

[0079] S42. The sound-absorbing material board and the perforated hollow ceramsite board are combined according to the set sound-absorbing composite board structure to obtain a sound-absorbing composite board. Selecting appropriate sound-absorbing materials to make the sound-absorbing material board can expand the application range of the composite board, obtain customized composite boards that are suitable for various environments, and utilize the advantages of various materials. Different combinations can produce synergistic effects, increase the multifunctionality of the sound-absorbing composite board, and further improve the sound absorption performance of the composite board.

[0080] The technical solution of the present invention will be described in detail below with reference to specific embodiments. The following specific embodiments may be combined or substituted with each other according to the actual situation, and the same or similar concepts or processes may not be described again in some embodiments.

[0081] Example 1:

[0082] Based on the above-mentioned method for manufacturing sound-absorbing composite panels using perforated hollow ceramsite boards, such as... Figure 1 and Figure 2 As shown, this embodiment provides a sound-absorbing composite panel based on perforated hollow ceramsite board, wherein the sound-absorbing material board includes perforated hollow ceramsite board 1 and glass wool board 2. The perforated hollow ceramsite board 1 is provided with sound-absorbing holes 11 of different diameters that are vertically and alternately distributed. The glass wool board 2 is provided with holes perpendicular to the board surface. The perforated hollow ceramsite board 1 and glass wool board 2 are stacked and bonded together.

[0083] Includes the following steps:

[0084] (1) Sludge preparation: 30 parts of hollow ceramsite with a particle size of 20-40 mesh, 45 parts of solid waste cementitious material and 20 parts of water are thoroughly mixed to obtain a uniformly mixed sludge.

[0085] (2) Injection molding, demolding and drying: The above-mentioned mud material is injected into the mold. In this embodiment, the mold is a plastic mold. The mold is vibrated to ensure complete filling. The mold is sealed with plastic wrap and cured at room temperature (curing temperature standard is between 10℃ and 25℃, humidity is between 55% and 85%) for 3 to 5 days to allow the water chemical reaction of the solid waste cementitious material to be complete. After demolding the above-formed blank, it is naturally dried in the air for 10 to 15 days to obtain hollow ceramsite board. It is naturally dried until the surface of the hollow ceramsite board is dry and there is no dampness when touched by hand.

[0086] (3) Substrate perforation: Perforated hollow ceramic particle board is prepared according to the designed structure using a perforation machine. In this embodiment, two kinds of sound-absorbing holes with different diameters are vertically arranged on the board surface. The diameters of the sound-absorbing holes are between 20mm and 60mm and 80mm and 120mm.

[0087] (4) Composite Panel Assembly: In this embodiment, the sound-absorbing material panel is a perforated hollow ceramsite board and a glass wool board. The perforated hollow ceramsite board and the glass wool board are stacked and bonded together to obtain a sound-absorbing composite panel. Glass wool boards have excellent sound absorption characteristics, effectively absorbing and weakening sound waves, reducing noise levels, and improving the indoor acoustic environment. They typically have high durability, are not easily corroded, decomposed, or affected by moisture, and therefore can maintain their performance for a long time. They are suitable for sound absorption needs in high-temperature environments. Furthermore, glass wool boards are easy to cut and process, and can be customized in shape and size according to specific needs, adapting to the design of various sound-absorbing structures. They also have the advantages of being recyclable and antibacterial. The structure of the sound-absorbing composite panel can be referenced... Figure 1 The sound absorption coefficient-frequency characteristics of the sound-absorbing composite panel under different pore size conditions are as follows: Figure 2 As shown, the composite board composed of perforated hollow ceramsite board and glass wool achieves an average sound absorption coefficient of 0.59 in the 100Hz–500Hz range without pores, and exceeds 0.65 in the same range with a pore size of 20mm. Under all conditions, the average sound absorption coefficient exceeds 0.4 in the 50Hz–1600Hz range. Therefore, it can be concluded that the sound absorption performance of the material can be controlled by adjusting the perforation depth and sound absorption structure of the hollow ceramsite board.

[0088] Example 2:

[0089] Based on the above-mentioned method for manufacturing sound-absorbing composite panels using perforated hollow ceramsite boards, such as... Figure 1 and Figure 3As shown, this embodiment provides a sound-absorbing composite panel based on a perforated hollow ceramsite board. The sound-absorbing material board includes a perforated hollow ceramsite board 1 and an 80% porosity mullite porous ceramic board 2. The perforated hollow ceramsite board 1 has sound-absorbing holes 11 of different diameters that are vertically and alternately distributed. The mullite porous ceramic board 2 has holes perpendicular to the board surface. The perforated hollow ceramsite board 1 and the 80% porosity mullite porous ceramic board 2 are stacked and bonded together.

[0090] Includes the following steps:

[0091] (1) Sludge preparation: 30 parts of hollow ceramsite with a particle size of 20-40 mesh, 45 parts of solid waste cementitious material and 20 parts of water are thoroughly mixed to obtain a uniformly mixed sludge.

[0092] (2) Injection molding, demolding and drying: The above-mentioned mud material is injected into the mold. In this embodiment, the mold is a plastic mold. The mold is vibrated to ensure complete filling. The mold is sealed with plastic wrap and cured at room temperature (curing temperature standard is between 10℃ and 25℃, humidity is between 55% and 85%) for 3 to 5 days to allow the water chemical reaction of the solid waste cementitious material to be complete. After demolding the above-formed blank, it is naturally dried in the air for 10 to 15 days to obtain hollow ceramsite board. It is naturally dried until the surface of the hollow ceramsite board is dry and there is no dampness when touched by hand.

[0093] (3) Substrate perforation: Perforated hollow ceramic particle board is prepared according to the designed structure using a perforation machine. In this embodiment, two kinds of sound-absorbing holes with different diameters are vertically arranged on the board surface. The diameters of the sound-absorbing holes are between 20mm and 60mm and 80mm and 120mm.

[0094] (4) Composite Panel: In this embodiment, the sound-absorbing material panel is a perforated hollow ceramsite panel and a mullite porous ceramic panel with an 80% open porosity. The perforated hollow ceramsite panel and the mullite porous ceramic panel with an 80% open porosity are stacked and bonded together to obtain a sound-absorbing composite panel. Mullite porous ceramic panels typically have excellent high-temperature resistance and high durability, and are not easily corroded, decomposed, or affected by moisture, making them suitable for sound absorption requirements in high-temperature environments. An 80% open porosity means a large number of pores, which helps to effectively capture and absorb sound waves, giving it excellent sound absorption performance, reducing noise levels, and improving the acoustic environment. Despite the high open porosity, mullite porous ceramics are usually lightweight materials and do not significantly increase the weight of the structure, making them suitable for applications requiring lightweight design. The sound-absorbing composite panel is obtained by combining the perforated hollow ceramsite panel and the mullite porous ceramic panel with an 80% open porosity. The sound absorption coefficient-frequency characteristics of this sound-absorbing composite panel under different pore size conditions are as follows: Figure 3As shown, the composite plate composed of perforated hollow ceramsite board and porous ceramic with 80% open porosity has a sound absorption coefficient of 0.41 at 100Hz when the pore size is 60mm, and a sound absorption coefficient as high as 0.78 at 100Hz when the pore size is 120mm.

[0095] Example 3:

[0096] Based on the above-mentioned method for manufacturing sound-absorbing composite panels using perforated hollow ceramsite boards, such as... Figure 1 As shown, this embodiment provides a sound-absorbing composite panel based on a perforated hollow ceramsite board. The sound-absorbing material panel includes a perforated hollow ceramsite board 1 and a mullite porous ceramic board 2 with a porosity of 90%. The perforated hollow ceramsite board 1 has sound-absorbing holes 11 with different pore sizes that are vertically staggered. The mullite porous ceramic board 2 has holes that are perpendicular to the board surface. The perforated hollow ceramsite board 1 and the mullite porous ceramic board 2 with a porosity of 90% are stacked and bonded together.

[0097] Includes the following steps:

[0098] (1) Sludge preparation: 30 parts of hollow ceramsite with a particle size of 20-40 mesh, 45 parts of solid waste cementitious material and 20 parts of water are thoroughly mixed to obtain a uniformly mixed sludge.

[0099] (2) Injection molding, demolding and drying: The above-mentioned mud material is injected into the mold. In this embodiment, the mold is a plastic mold. The mold is vibrated to ensure complete filling. The mold is sealed with plastic wrap and cured at room temperature (curing temperature standard is between 10℃ and 25℃, humidity is between 55% and 85%) for 3 to 5 days to allow the water chemical reaction of the solid waste cementitious material to be complete. After demolding the above-formed blank, it is naturally dried in the air for 10 to 15 days to obtain hollow ceramsite board. It is naturally dried until the surface of the hollow ceramsite board is dry and there is no dampness when touched by hand.

[0100] (3) Substrate perforation: Perforated hollow ceramic particle board is prepared according to the designed structure using a perforation machine. In this embodiment, two kinds of sound-absorbing holes with different diameters are vertically arranged on the board surface. The diameters of the sound-absorbing holes are between 20mm and 60mm and 80mm and 120mm.

[0101] (4) Composite Board: In this embodiment, the sound-absorbing material board is a perforated hollow ceramsite board and a mullite porous ceramic board with 90% open porosity. The perforated hollow ceramsite board and the mullite porous ceramic board with 90% open porosity are stacked and bonded together to obtain a sound-absorbing composite board. Due to its higher porosity, the mullite porous ceramic board with 90% open porosity can provide superior sound absorption performance. More pores mean a larger sound-absorbing surface area, thus it can more effectively capture and absorb sound waves, providing a higher sound absorption effect and reducing more noise.

[0102] In addition, sound absorption and energy absorption tests were conducted on the sound-absorbing composite panels obtained in Examples 1, 2 and 3. The test frequency range was 50Hz to 1600Hz, and the perforated hollow ceramic particle panels were tested with a pore size of 60mm. The main test results are summarized in Table 1.

[0103] Table 1. Sound absorption performance of the sound-absorbing composite panel based on perforated hollow ceramsite board.

[0104]

[0105] Based on the above embodiments and numerous laboratory experimental results, it can be seen that the particle size of hollow ceramic particles has a significant impact on the compressive strength and sound absorption performance of the sound-absorbing board. Reasonable adjustment of particle size can regulate the overall performance of the sound-absorbing board.

[0106] Example 4:

[0107] Based on the above-mentioned method for manufacturing sound-absorbing composite panels using perforated hollow ceramsite boards, such as... Figure 4 As shown, this embodiment provides a sound-absorbing composite panel based on a perforated hollow ceramsite board, comprising a perforated hollow ceramsite board 1, a glass wool board 2, and a mullite porous ceramic board 3 with an 80% open porosity. The perforated hollow ceramsite board 1 has sound-absorbing holes 11 of different diameters that are vertically and alternately distributed. The glass wool board 2 and the mullite porous ceramic board 3 with an 80% open porosity have holes perpendicular to the board surface. The perforated hollow ceramsite board 1, the glass wool board 2, and the mullite porous ceramic board 3 with an 80% open porosity are stacked and bonded together.

[0108] Understandably, the order in which glass wool board 2, mullite porous ceramic board 3, and perforated hollow ceramsite board 1 are stacked and bonded can be adjusted according to different design requirements.

[0109] Includes the following steps:

[0110] (1) Sludge preparation: 30 parts of hollow ceramsite with a particle size of 20-40 mesh, 45 parts of solid waste cementitious material and 20 parts of water are thoroughly mixed to obtain a uniformly mixed sludge.

[0111] (2) Injection molding, demolding and drying: The above-mentioned mud material is injected into the mold. In this embodiment, the mold is a plastic mold. The mold is vibrated to ensure complete filling. The mold is sealed with plastic wrap and cured at room temperature (curing temperature standard is between 10℃ and 25℃, humidity is between 55% and 85%) for 3 to 5 days to allow the water chemical reaction of the solid waste cementitious material to be complete. After demolding the above-formed blank, it is naturally dried in the air for 10 to 15 days to obtain hollow ceramsite board. It is naturally dried until the surface of the hollow ceramsite board is dry and there is no dampness when touched by hand.

[0112] (3) Substrate perforation: Perforated hollow ceramic particle board is prepared according to the designed structure using a perforation machine. In this embodiment, two kinds of sound-absorbing holes with different diameters are vertically arranged on the board surface. The diameters of the sound-absorbing holes are between 20mm and 60mm and 80mm and 120mm.

[0113] (4) Composite board: In this embodiment, the sound-absorbing material board is a combination of glass wool board and mullite porous ceramic board. The perforated hollow ceramic particle board, glass wool board and mullite porous ceramic board are stacked and glued according to the designed sound-absorbing structure to obtain a sound-absorbing structure composite board.

[0114] Multi-layer composites can achieve multi-layer sound-absorbing structures, improving acoustic performance. Each material can play its own role in sound absorption, sound insulation, or heat insulation, working synergistically to make the sound absorption effect more significant. Perforated hollow ceramic particle boards, glass wool boards, and mullite porous ceramic boards all have certain strength and stability. By using them in combination, the overall strength of the sound-absorbing structure can be improved, ensuring long-term performance stability.

[0115] In addition to the preferred embodiments described above, the present invention has other embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection claimed by the present invention.

Claims

1. A sound-absorbing composite panel based on perforated hollow ceramsite board, characterized in that, The sound-absorbing composite panel is composed of at least two sound-absorbing material panels, at least one of which is a perforated hollow ceramsite panel. Each sound-absorbing material panel includes a panel surface opposite each other in the thickness direction and an end face surrounding the panel surface. The perforated hollow ceramsite panel has multiple sound-absorbing holes of different diameters. These sound-absorbing holes are obtained by drilling perpendicular to the panel surface using a drilling machine. The drilling depth of each sound-absorbing hole accounts for 80% to 90% of the total thickness of the hollow ceramsite panel in the drilling direction, and the opening area of ​​each sound-absorbing hole on the hollow ceramsite panel accounts for 80% to 90% of the total area of ​​the hollow ceramsite panel. The diameter of each sound-absorbing hole is between 20mm and 120mm, and the mesh size of the ceramsite in the perforated hollow ceramsite panel is between 20 and 40 mesh. The perforated hollow ceramsite panel includes an adjacent first base layer and a second base layer. The diameter of the sound-absorbing holes in the first base layer is between 20mm and 60mm, and the diameter of the sound-absorbing holes in the second base layer is between 80mm and 120mm.

2. The sound-absorbing composite panel based on perforated hollow ceramsite board according to claim 1, characterized in that, The perforated hollow ceramsite board includes an adjacent base layer, the base layer comprising ceramsite of at least two mesh sizes; or, the ceramsite in the perforated hollow ceramsite board is composed of a mixture of ceramsite of at least two mesh sizes.

3. A method for manufacturing a sound-absorbing composite panel based on perforated hollow ceramsite board, used to manufacture the sound-absorbing composite panel based on perforated hollow ceramsite board as described in any one of claims 1 to 2, characterized in that, Includes the following steps: S1. Hollow ceramsite, solid waste cementitious material and water are mixed evenly to obtain slurry; S2. Pour the slurry into the mold and vibrate the mold until the slurry completely fills the mold. Place the completely filled mold in a humid environment for curing. After curing, remove the molded product from the mold and let it dry naturally to obtain a hollow ceramsite board. S3. Use a drilling machine with preset perforation size, depth and distribution to drill holes in the hollow ceramsite board to obtain a perforated hollow ceramsite board. S4. Select sound-absorbing materials to make a sound-absorbing material board, and combine the perforated hollow ceramic particle board with the sound-absorbing material board to obtain a sound-absorbing composite board.

4. The method for manufacturing a sound-absorbing composite panel based on perforated hollow ceramsite board according to claim 3, characterized in that, S1 includes the following steps: S11. Select the mesh size of the hollow ceramsite and obtain the required amount of hollow ceramsite, total solid waste gel material, and water. S12. Based on the amount of hollow ceramsite, the amount of solid waste gel material, and the amount of water, the hollow ceramsite, the solid waste gel material, and the water are mixed to obtain a mixture; S13. The mixture is stirred evenly to obtain a slurry.

5. The method for manufacturing a sound-absorbing composite panel based on perforated hollow ceramsite board according to claim 3, characterized in that, S2 includes the following steps: S21. Pour the slurry into the mold, vibrate the mold to expel the gas and make the slurry completely fill the mold; S22. Seal the mold after it is fully filled and degassed with plastic wrap and let it cure at room temperature until the chemical reaction of the slurry is complete. S23. Demold the cured molded product to obtain the molded product. After the molded product dries naturally, hollow ceramic granule board is obtained.

6. The method for manufacturing a sound-absorbing composite panel based on perforated hollow ceramsite board according to claim 3, characterized in that, S3 includes the following steps: S31. Set appropriate hole size, hole depth and hole distribution on the punching machine; S32. Use a drilling machine with pre-set perforation size, perforation depth and perforation distribution to drill holes in the hollow ceramsite board to obtain a perforated hollow ceramsite board.

7. The method for manufacturing a sound-absorbing composite panel based on perforated hollow ceramsite board according to claim 3, characterized in that, S4 includes the following steps: S41. Select appropriate sound-absorbing materials to make sound-absorbing material boards; S42. The sound-absorbing material board and the perforated hollow ceramic particle board are stacked and bonded together to obtain a sound-absorbing composite board.

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