Waterproof sound insulation suspended ceiling and preparation method thereof

Abstract

The invention relates to the technical field of ceilings, and particularly discloses a waterproof sound insulation suspended ceiling and a preparation method thereof. The waterproof sound insulation suspended ceiling comprises a base plate layer, a sound insulation layer and a waterproof coating, the base plate layer is located between the sound insulation layer and the waterproof coating, the base plate layer is a polyvinyl chloride plate layer, and the base plate layer is prepared from, by weight, 60-80 parts of polyvinyl chloride, 20-30 parts of polyurethane, 5-8 parts of glass fibers and 10-15 parts of heavy calcium carbonate. 10-20 parts of nano silicon dioxide, 1-3 parts of a coupling agent and 10-15 parts of a plasticizer; the ceiling prepared by the invention has better waterproof performance and sound insulation effect through the synergistic effect of all the components.

Description

Technical Field

[0001] The present application relates to the field of ceiling technology, and in particular to a waterproof and soundproof suspended ceiling and a preparation method thereof. Background Art

[0002] The ceiling is the top surface of a building, which covers beams, pipes, heat insulation, sound insulation, etc. The design of the ceiling is wonderful and varied, and each one can create a different decorative effect. With the improvement of the quality of life, people have higher requirements for the sound environment and humidity control of indoor space.

[0003] Currently, the suspended ceilings on the market are mainly made of gypsum board. Gypsum board ceilings have poor waterproof and moisture-proof properties and poor sound insulation effects. When the gypsum board absorbs water and becomes damp, its hardness decreases, and in severe cases it may even delaminate, seriously shortening the service life of the ceiling. Summary of the invention

[0004] In order to improve the existing ceiling waterproof and sound insulation problems, the present application provides a waterproof and soundproof suspended ceiling and a preparation method thereof.

[0005] In a first aspect, the present application provides a waterproof and soundproof suspended ceiling, which adopts the following technical solution: A waterproof and soundproof suspended ceiling comprises a substrate layer, a sound insulation layer and a waterproof coating, wherein the substrate layer is located between the sound insulation layer and the waterproof coating, the substrate layer is a polyvinyl chloride board layer, and the substrate layer comprises the following raw materials in parts by weight: 60-80 parts of polyvinyl chloride, 20-30 parts of polyurethane, 5-8 parts of glass fiber, 10-15 parts of heavy calcium carbonate, 10-20 parts of nano silicon dioxide, 1-3 parts of coupling agent, and 10-15 parts of plasticizer.

[0006] By adopting the above technical solution, polyvinyl chloride can improve the waterproof and moisture-proof performance of the substrate layer. By introducing polyurethane macromolecular chains into the polyvinyl chloride system, after being subjected to the vibration of sound waves, the movement mode of polyvinyl chloride and polyurethane molecular weight is different from that of sound waves, thereby consuming more sound wave movement energy and enhancing the sound insulation effect of the substrate layer. The addition of nano-silicon dioxide and heavy calcium carbonate particles can increase the density of the substrate layer system, consume the energy of sound waves, and improve the sound insulation effect of the substrate layer. At the same time, heavy calcium carbonate also has a good waterproof effect, which improves the waterproof performance of the ceiling. Adding glass fiber to the substrate layer can achieve a sound-absorbing effect, absorb sound waves, and enhance the sound insulation effect. Glass fiber can enhance the strength and toughness of the substrate layer, improve the stability of the substrate layer, and reduce deformation of the substrate layer.

[0007] Preferably, the sound insulation layer comprises the following raw materials in parts by weight: 3-5 parts of paraffin, 1-3 parts of plant fiber, 20-30 parts of gypsum, 5-10 parts of sound absorbing material, 5-10 parts of binder, and 0.5-0.8 parts of water reducing agent.

[0008] By adopting the above technical solution, paraffin wax has good damping performance, can absorb and transform sound wave energy, reduce the reflection and transmission of sound, reduce the penetration of sound, and improve the sound insulation effect of the sound insulation layer. At the same time, paraffin wax can also form a waterproof film to prevent moisture penetration, reduce the erosion of moisture on the sound insulation layer, and improve the waterproof effect of the sound insulation layer. Plant fiber has a porous structure that can absorb sound waves, reduce the reflection and penetration of sound, and has a good sound absorption effect, thereby enhancing the sound insulation effect of the sound insulation layer. At the same time, plant fiber also has a certain damping effect, absorbs vibration energy, and reduces the propagation of sound. Gypsum has good fire resistance and can also absorb an appropriate amount of sound waves to improve the thermal stability of the ceiling.

[0009] Preferably, the sound absorbing material is one of hollow microbeads and expanded perlite.

[0010] By adopting the above technical solution, hollow microspheres and expanded perlite have a porous structure, which can reflect and scatter sound waves multiple times in the cavity, consume sound energy, reduce sound intensity, and thus improve the sound insulation effect of the sound insulation layer. At the same time, hollow microspheres and expanded perlite are lightweight materials that can reduce the weight of the sound insulation layer and reduce the pressure on the top surface of the building. At the same time, they can also improve the thermal insulation performance of the sound insulation layer, reduce heat transfer, and maintain a stable indoor temperature.

[0011] Preferably, the sound absorbing material is modified by sodium methyl silicate.

[0012] By adopting the above technical scheme, sodium methyl silicate can form chemical bonds with the surface of hollow microspheres and expanded perlite to form a strong hydrophobic silicone resin film, which is evenly distributed on the pore walls of the hollow microspheres and expanded perlite, and does not block the capillary channels of the sound-absorbing material. Water molecules cannot penetrate into the hollow microspheres and expanded perlite particles, which makes the sound-absorbing material have a better hydrophobic effect and improves the waterproof effect of the ceiling.

[0013] Preferably, the modification method comprises the following specific steps: diluting sodium methyl silicate and mixing it with the sound-absorbing material, soaking it at 40-60° C., blowing it to dry it, and drying it to constant weight to obtain the modified sound-absorbing material.

[0014] Preferably, the binder is a mixture of water glass and silica sol, and the mass ratio of the water glass to the silica sol is 1:(2-3).

[0015] By adopting the above technical solution, water glass and silica sol as binders can promote the components in the sound insulation layer system to bond together to form a whole, improve the structural stability and mechanical strength of the sound insulation layer, reduce the phenomenon of stratification and shedding during the use of the sound insulation layer, and improve the durability of the sound insulation layer. Water glass and silica sol have good durability, can maintain good structural stability and bonding strength in a humid environment, and improve the structural stability and durability of the ceiling.

[0016] Preferably, the waterproof coating is a polyurethane waterproof coating.

[0017] By adopting the above technical solution, the polyurethane waterproof coating has good adhesion to the substrate layer, forming a continuous and dense waterproof film on the surface of the substrate layer, which can effectively prevent water penetration and improve the waterproof and moisture-proof performance of the ceiling. At the same time, the polyurethane waterproof coating has good elasticity and ductility, can adapt to the slight deformation and displacement of the substrate layer, reduce the cracking of the waterproof coating caused by the deformation of the substrate, and improve the durability of the waterproof performance of the ceiling.

[0018] In a second aspect, the present application provides a method for preparing a waterproof and soundproof suspended ceiling, using the following technical solution: A method for preparing a waterproof and soundproof suspended ceiling comprises the following specific steps: Polyvinyl chloride, glass fiber, heavy calcium carbonate, nano-silicon dioxide, coupling agent and plasticizer are mixed, polyurethane is added after internal kneading and the kneading is continued to form a substrate layer mixture, which is then formed by open kneading to form a substrate layer; the substrate layer is then compounded with the sound insulation layer, hot-pressed, and a layer of waterproof coating is applied on the side of the substrate layer away from the sound insulation layer to obtain a waterproof and soundproof suspended ceiling.

[0019] By adopting the above technical solution, the prepared ceiling has good waterproof and sound insulation effects, can reduce the penetration of water molecules, and has more lasting structural stability.

[0020] Preferably, paraffin, plant fiber, gypsum, sound-absorbing material, adhesive and water-reducing agent are mixed and melted, extruded on the surface of the substrate layer, cooled and shaped, and hot-pressed to form a sound insulation layer; and then a layer of waterproof coating is applied on the side of the base layer away from the sound insulation layer to obtain a waterproof and sound-insulating ceiling.

[0021] Preferably, the hot pressing temperature is 130-160°C.

[0022] In summary, this application has the following beneficial effects: 1. Since the base plate, sound insulation layer and waterproof coating are combined in the present application, and polyvinyl chloride and polyurethane are used in the raw materials of the base plate, the base plate can have a good waterproof and moisture-proof effect, while consuming the energy of sound waves and improving the sound insulation effect of the base plate. Nano-silicon dioxide, heavy calcium carbonate particles and glass fiber can enhance the density of the base plate, absorb sound waves and improve the sound insulation effect of the base plate.

[0023] 2. In this application, the good damping performance of paraffin is used in the sound insulation layer to absorb and transform the sound wave energy, and at the same time form a waterproof film to reduce the penetration of water molecules and improve the sound insulation and waterproof and moisture-proof effects of the ceiling. Hollow microspheres and expanded perlite seat sound-absorbing materials with porous structures are used to reflect and scatter sound waves multiple times, reduce the sound intensity, and thus improve the sound insulation effect of the ceiling. At the same time, the sound-absorbing material is modified with sodium methyl silicate to make the sound-absorbing material have a better water-repellent effect and improve the waterproof and moisture-proof effect of the ceiling. DETAILED DESCRIPTION

[0024] The present application is further described in detail below with reference to the embodiments.

[0025] All raw materials in the examples are commercially available. Example

[0026] Example 1 This embodiment provides a waterproof and soundproof ceiling, which comprises a waterproof coating, a substrate layer, and a soundproof layer from top to bottom. The waterproof coating is a polyurethane waterproof coating, wherein the substrate layer comprises the following raw materials in parts by weight: 70 kg of polyvinyl chloride, 25 kg of polyurethane, 7 kg of glass fiber, 13 kg of heavy calcium carbonate, 15 kg of nano-silicon dioxide, 2 kg of coupling agent, and 13 kg of plasticizer. The molecular weight of polyvinyl chloride is 40,000, the molecular weight of polyurethane is 20,000, the average particle size of nano-silicon dioxide is 50-100 nm, the coupling agent is KH-560 coupling agent, and the plasticizer is dioctyl phthalate.

[0027] The sound insulation layer includes the following raw materials in parts by weight: 25 kg of gypsum, 8 kg of sound absorbing material, 2 kg of plant fiber, and 0.7 kg of water reducing agent. The sound absorbing material is expanded perlite, and the water reducing agent is calcium lignin sulfonate.

[0028] The method for preparing a waterproof and soundproof suspended ceiling comprises the following specific steps: S1: Mix polyvinyl chloride, glass fiber, heavy calcium carbonate, nano-silicon dioxide, coupling agent and plasticizer, knead them at 170°C for 5 minutes, add polyurethane and continue kneading for 8 minutes to form a substrate layer mixture, and then knead the lower sheet to form the substrate layer.

[0029] S2: Mix gypsum, sound-absorbing material and water-reducing agent, melt and extrude them on the surface of the substrate layer at 140°C, cool and shape them, and hot press them at 140°C for 5s to form a sound insulation layer. Finally, apply a layer of waterproof coating on the side of the base layer away from the sound insulation layer to make a waterproof and soundproof ceiling.

[0030] Example 2 The difference between Example 2 and Example 1 is that the amount of polyvinyl chloride used in the substrate layer raw material is 60kg, the amount of polyurethane used is 30kg, the amount of glass fiber used is 5kg, the amount of heavy calcium carbonate used is 15kg, the amount of nano-silicon dioxide used is 10kg, the amount of coupling agent used is 1kg, and the amount of plasticizer used is 10kg.

[0031] Example 3 The difference between Example 3 and Example 1 is that the amount of polyvinyl chloride used in the substrate layer raw material is 80 kg, the amount of polyurethane used is 20 kg, the amount of glass fiber used is 8 kg, the amount of heavy calcium carbonate used is 10 kg, the amount of nano-silicon dioxide used is 20 kg, the amount of coupling agent used is 3 kg, and the amount of plasticizer used is 15 kg.

[0032] Example 4 The difference between Example 4 and Example 1 is that the sound insulation layer raw material also includes 8 kg of adhesive, wherein the adhesive is water glass.

[0033] The method for preparing a waterproof and soundproof suspended ceiling comprises the following specific steps: S1: Mix polyvinyl chloride, glass fiber, heavy calcium carbonate, nano-silicon dioxide, coupling agent and plasticizer, knead them at 170°C for 5 minutes, add polyurethane and continue kneading for 8 minutes to form a substrate layer mixture, and then knead the lower sheet to form the substrate layer.

[0034] S2: Gypsum, sound-absorbing material, plant fiber, binder and water-reducing agent are mixed, melted and extruded on the surface of the substrate layer at 140°C, cooled and shaped, and hot-pressed at 140°C for 5s to form a sound insulation layer. Finally, a waterproof coating is applied on the side of the base layer away from the sound insulation layer to obtain a waterproof and soundproof ceiling.

[0035] Example 5 The difference between Example 5 and Example 4 is that the raw materials of the sound insulation layer also include 4 kg of paraffin.

[0036] The method for preparing a waterproof and soundproof suspended ceiling comprises the following specific steps: S1: Mix polyvinyl chloride, glass fiber, heavy calcium carbonate, nano-silicon dioxide, coupling agent and plasticizer, knead them at 170°C for 5 minutes, add polyurethane and continue kneading for 8 minutes to form a substrate layer mixture, and then knead the lower sheet to form the substrate layer.

[0037] S2: Gypsum, sound-absorbing material, paraffin, plant fiber, binder and water-reducing agent are mixed, melted and extruded on the surface of the substrate layer at 140°C, cooled and shaped, and hot-pressed at 140°C for 5s to form a sound insulation layer. Finally, a waterproof coating is applied on the side of the base layer away from the sound insulation layer to obtain a waterproof and soundproof ceiling.

[0038] Example 6 The difference between Example 6 and Example 5 is that the amount of paraffin used in the sound insulation layer raw materials is 3 kg, the amount of plant fiber used is 3 kg, the amount of gypsum used is 20 kg, the amount of sound absorbing material used is 5 kg, the amount of adhesive used is 5 kg, and the amount of water reducing agent used is 0.5 kg.

[0039] Example 7 The difference between Example 7 and Example 5 is that the amount of paraffin used in the sound insulation layer raw materials is 5 kg, the amount of plant fiber used is 1 kg, the amount of gypsum used is 30 kg, the amount of sound absorbing material used is 10 kg, the amount of adhesive used is 10 kg, and the amount of water reducing agent used is 0.8 kg.

[0040] Example 8 The difference between Example 8 and Example 5 is that the sound absorbing material in the sound insulation layer raw material is hollow microspheres. The particle size of the hollow microspheres is 800 meshes, which are purchased from Shanghai Gerunya Nanomaterials Co., Ltd.

[0041] Example 9 The difference between Example 9 and Example 5 is that the binder in the raw material of the sound insulation layer is a mixture of water glass and silica sol, and the mass ratio of water glass to silica sol is 1:2.5.

[0042] Example 10 The difference between Example 10 and Example 9 is that the sound absorbing material in the raw material of the sound insulation layer is modified by sodium methyl silicate.

[0043] The method for preparing a waterproof and soundproof suspended ceiling comprises the following specific steps: S1: Mix polyvinyl chloride, glass fiber, heavy calcium carbonate, nano-silicon dioxide, coupling agent and plasticizer, knead them at 170°C for 5 minutes, add polyurethane and continue kneading for 8 minutes to form a substrate layer mixture, and then knead the lower sheet to form the substrate layer.

[0044] S2: dilute sodium methyl silicate with 45% sodium hydroxide to form a 4% sodium methyl silicate solution by mass, then put the sound-absorbing material into the sodium methyl silicate solution, soak it at 50° C. for 1 hour, blow dry it, and dry it to constant weight to obtain a modified sound-absorbing material.

[0045] S2: Gypsum, modified sound-absorbing material, paraffin, plant fiber, binder and water reducer are mixed, melted and extruded on the surface of the substrate layer at 140°C, cooled and shaped, and hot pressed at 140°C for 5s to form a sound insulation layer. Finally, a waterproof coating is applied on the side of the base layer away from the sound insulation layer to obtain a waterproof and soundproof ceiling.

[0046] Comparative Example Comparative Example 1 The difference between Comparative Example 1 and Example 1 is that the waterproof and soundproof suspended ceiling does not use a sound insulation layer.

[0047] The method for preparing a waterproof and soundproof suspended ceiling comprises the following specific steps: Polyvinyl chloride, glass fiber, heavy calcium carbonate, nano-silicon dioxide, coupling agent and plasticizer are mixed, kneaded at 170°C for 5 minutes, polyurethane is added and kneaded for 8 minutes to form a substrate layer mixture, and then the lower sheet is formed to form a substrate layer. A layer of waterproof coating is applied on the surface of the base layer to make a waterproof and soundproof ceiling.

[0048] Comparative Example 2 The difference between Comparative Example 2 and Example 1 is that polyurethane is not used in the raw material of the substrate layer.

[0049] The method for preparing a waterproof and soundproof suspended ceiling comprises the following specific steps: S1: polyvinyl chloride, glass fiber, heavy calcium carbonate, nano silicon dioxide, coupling agent and plasticizer are mixed, and kneaded at 170°C for 20 minutes to form a substrate layer mixture, which is then kneaded to form a substrate layer.

[0050] S2: Mix gypsum, sound-absorbing material and water-reducing agent, melt and extrude them on the surface of the substrate layer at 140°C, cool and shape them, and hot press them at 140°C for 5s to form a sound insulation layer. Finally, apply a layer of waterproof coating on the side of the base layer away from the sound insulation layer to make a waterproof and soundproof ceiling.

[0051] Comparative Example 3 The difference between Comparative Example 3 and Example 1 is that glass fiber, heavy calcium carbonate and nano-silicon dioxide are not used in the raw materials of the substrate layer.

[0052] Performance testing The following performance tests were performed on the waterproof and soundproof suspended ceilings provided in Examples 1-10 and Comparative Examples 1-3. The specific test results are shown in Table 1.

[0053] Detection Methods 1. Sound insulation performance The sound insulation effect of the suspended ceiling prepared in this application was tested with reference to the standard GB / T 19889.7-2005 "Acoustic buildings and building components sound insulation measurement Part 7: Field measurement of floor impact sound insulation".

[0054] 2. Absorption and moisture-proof effect With reference to the standard of GB / T1034-1998 "Test method for water absorption of plastics", the sample was placed in air with a relative humidity of 50% to test the waterproof effect of the suspended ceiling prepared in the present application.

[0055] Table 1: Performance test results data table It can be seen from the performance test results that the waterproof and sound-insulating suspended ceiling prepared in the present application has lower water absorption and higher sound insulation effect.

[0056] By comparing Examples 4-5 with Example 1, it can be seen that the comprehensive performance of the ceilings prepared in Examples 4 and 5 is better than that in Example 1, and the comprehensive performance of Example 5 is the best. It is further explained that adding an appropriate amount of paraffin wax to the sound insulation layer can enhance the waterproof effect and sound insulation effect of the ceiling. Using a binder in the raw material of the sound insulation layer can also improve the structural stability and strength of the ceiling and reduce the phenomenon of delamination and falling off of the ceiling. By comparing Example 9 with Example 5, it can be seen that the binder used in Example 9 has a better effect.

[0057] In Example 10, the sound-absorbing material is modified by sodium methyl silicate. From the performance test results, it can be seen that the waterproof effect of the ceiling is further improved, and the sound insulation effect is also improved.

[0058] By comparing Comparative Examples 1-3 with Example 1, it can be seen that Comparative Example 1 does not use a sound insulation layer, Comparative Example 2 does not use polyurethane, and Comparative Example 3 does not use glass fiber, heavy calcium carbonate, and nano-silicon dioxide. From the performance test results, it can be seen that the comprehensive performance of the ceiling is significantly reduced, and the ceiling prepared in Comparative Example 1 can no longer meet the sound insulation requirements.

[0059] This specific embodiment is merely an explanation of the present application and is not a limitation of the present application. After reading this specification, those skilled in the art may make modifications to the present embodiment without any creative contribution as needed, but such modifications are protected by the patent law as long as they are within the scope of the claims of the present application.

Claims

1. A waterproof and soundproof suspended ceiling, characterized in that: The invention comprises a substrate layer, a sound insulation layer and a waterproof coating, wherein the substrate layer is located between the sound insulation layer and the waterproof coating, the substrate layer is a polyvinyl chloride plate layer, and the substrate layer comprises the following raw materials in parts by weight: 60-80 parts of polyvinyl chloride, 20-30 parts of polyurethane, 5-8 parts of glass fiber, 10-15 parts of heavy calcium carbonate, 10-20 parts of nano silicon dioxide, 1-3 parts of coupling agent and 10-15 parts of plasticizer.

2. The waterproof and soundproof suspended ceiling according to claim 1, characterized in that: The sound insulation layer comprises the following raw materials in parts by weight: 3-5 parts of paraffin wax, 1-3 parts of plant fiber, 20-30 parts of gypsum, 5-10 parts of sound absorbing material, 5-10 parts of adhesive, and 0.5-0.8 parts of water reducing agent.

3. The waterproof and soundproof suspended ceiling according to claim 2, characterized in that: The sound absorbing material is one of hollow microbeads and expanded perlite.

4. The waterproof and soundproof suspended ceiling according to claim 3, characterized in that: The sound absorbing material is modified by sodium methyl silicate.

5. The waterproof and soundproof suspended ceiling according to claim 4, characterized in that: The modification method comprises the following specific steps: diluting sodium methyl silicate and mixing it with the sound absorbing material, soaking it at 40-60° C., drying it by blasting, and drying it to constant weight to obtain the modified sound absorbing material.

6. The waterproof and soundproof suspended ceiling according to claim 2, characterized in that: The binder is a mixture of water glass and silica sol, and the mass ratio of the water glass to the silica sol is 1:(2-3).

7. The waterproof and soundproof suspended ceiling according to claim 1, characterized in that: The waterproof coating is a polyurethane waterproof coating.

8. A method for preparing a waterproof and soundproof suspended ceiling according to any one of claims 1 to 7, characterized in that: The specific steps include: Polyvinyl chloride, glass fiber, heavy calcium carbonate, nano-silicon dioxide, coupling agent and plasticizer are mixed, polyurethane is added after internal kneading and the kneading is continued to form a substrate layer mixture, which is then formed by open kneading to form a substrate layer; the substrate layer is then compounded with the sound insulation layer, hot-pressed, and a layer of waterproof coating is applied on the side of the substrate layer away from the sound insulation layer to obtain a waterproof and soundproof suspended ceiling.

9. The method for preparing a waterproof and soundproof suspended ceiling according to claim 8, characterized in that: Paraffin wax, plant fiber, gypsum, sound-absorbing material, adhesive and water-reducing agent are mixed and melted, extruded on the surface of the substrate layer, cooled and shaped, and hot-pressed to form a sound insulation layer; then a layer of waterproof coating is applied on the side of the substrate layer away from the sound insulation layer to obtain a waterproof and sound-insulating ceiling.

10. The method for preparing a waterproof and soundproof suspended ceiling according to claim 9, characterized in that: The hot pressing temperature is 130-160°C.

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