Flexible lightweight multilayer panel for soundproof applications in buildings

Abstract

The invention provides a flexible light sound insulation panel which is composed of a plurality of layers. The plurality of layers are arranged in the sequence of a high-density sound insulation layer, a sound reduction layer, a medium-density sound reflection layer, a low-density sound absorption layer, a medium-density sound reflection layer, a sound reduction layer and a high-density sound insulation layer. And the silencing layer is made of polyurethane foam. According to ASTM E90, the flexible lightweight multilayer panel has a sound propagation level (STC) of at least 40 dB.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. patent application No. 18 / 489,878, filed on October 19, 2023, the disclosure of which is incorporated herein by reference. Technical Field

[0002] The present invention generally relates to a flexible, lightweight, multi-layer panel for use in soundproofing applications. More particularly, the present invention relates to lightweight polyurethane foams for use in soundproofing and acoustic insulation. Background Art

[0003] Nowadays, noise pollution brings troubles to people. The most common health problem caused by it is noise-induced hearing loss (NIHL). Exposure to loud noise can also cause high blood pressure, heart disease, sleep disorders and stress. In addition, noise pollution has many sources, including but not limited to traffic noise, industrial noise, community noise, family, aircraft and ship noise. In order to eliminate the adverse effects of noise on people, an effective method is to increase the sound propagation loss by using sound reflection and absorption. Many different materials can be used as building materials for sound insulation and sound absorption, which are based on the sound propagation mechanism of reflection or absorption of sound.

[0004] Building materials with soundproofing properties are dense and heavy materials that reflect sound back into the room without penetrating the other side. To increase the sound transmission loss (effectiveness of soundproofing properties), building design materials use mineral wool, fiberglass or foam as cavity partitions, wood fillers and metal partitions. The noise control mechanism of building materials is achieved when the metal sheet or hard wall layer from the outside reflects the sound; while the lining mineral wool or fiberglass from the inside absorbs the transmitted sound. This batt design can minimize the transmission of sound from the inside to the outside, and vice versa.

[0005] However, the above materials with sound insulation properties have the following limitations: (1) The total weight of the sound insulation panel is heavy. In order to increase the sound insulation properties, a common method is to increase the surface density of the sound insulation material according to the mass law. However, this makes the product heavier, which is not popular in the market that pursues light weight. (2) The sandwich design is an improved method to reduce weight while maintaining STC. However, the simple sandwich design does not maximize the sound insulation properties because the function of each layer is limited. For example, the dense layer only plays a sound insulation role, but has no sound-absorbing effect that can be considered to further reduce sound transmission.

[0006] Therefore, there is a need in the art for a lightweight building material with high sound insulation properties. The present invention addresses this need. Summary of the invention

[0007] In order to solve the presented technical problems, flexible lightweight building materials with a multi-layer sound insulation design have been developed, which are able to achieve a sound transmission class (STC) of at least 40 dB as defined in accordance with ASTM E90.

[0008] In a first aspect, the present invention provides a flexible lightweight multilayer panel for sound insulation applications in construction. The lightweight multilayer panel comprises: at least two high-density sound insulation layers (1); at least two sound-absorbing layers (2); at least two medium density sound reflecting layers (3); and At least one low-density sound-absorbing layer (4).

[0009] In one embodiment, the flexible lightweight building material is a seven-layer sound insulation design, wherein the layers are arranged in the order of a high-density sound insulation layer (1), a sound-absorbing layer (2), a medium-density sound reflection layer (3), a low-density sound absorption layer (4), a medium-density sound reflection layer (3), a sound-absorbing layer (2), and a high-density sound insulation layer (1).

[0010] In one embodiment, the high-density sound insulation layer (1) comprises a polymer composite material, wherein the polymer composite material includes polyvinyl chloride, chlorinated polyethylene or a combination thereof.

[0011] In one embodiment, the high-density sound insulation layer (1) has a Shore hardness of 40A to 60A, a hardness of 2.0g / cm 3 To 2.3g / cm 3 density and 5mm to 6mm thickness.

[0012] In one embodiment, the sound-absorbing layer (2) contains polyurethane foam. The polyurethane foam comprises: (a) a first reaction composition (A side) comprising at least one aromatic isocyanate component having an isocyanate functionality ranging from about 2 to about 2.5; and (b) a second reaction composition (B side) having: A diol having a hydroxyl value of 380 to 480 mgKOH / g; A polyether polyol having a hydroxyl value of 140 to 330 mgKOH / g; A polymer polyol having a hydroxyl value of 20 to 30 mgKOH / g; catalyst; Foam stabilizers; and water.

[0013] In one embodiment, the first reactant composition and the second reactant composition are contacted at a stoichiometric ratio of NCO:OH functionality of 0.9:1 to 1.4:1.

[0014] Preferably, the first reactant composition and the second reactant composition are contacted at a stoichiometric ratio of NCO:OH functionality of 1.1:1 to 1.3:1.

[0015] In one embodiment, the at least one aromatic isocyanate component comprises an aromatic diol and a polyisocyanate.

[0016] In one embodiment, the diol is used to enhance the mechanical strength of the polyurethane foam and constitutes a weight percentage ranging from 2% to 8% based on the total weight of the plurality of polyols.

[0017] In one embodiment, the polyether polyol is used to enhance the mechanical strength and adjust the glass transition temperature of the polyurethane foam, and constitutes 25 to 40 weight percent of the total weight of the plurality of polyols.

[0018] In one embodiment, the polymer polyol is used to adjust the softness and glass transition temperature of the polyurethane foam, and constitutes 45% to 70% by weight of the total weight of the plurality of polyols.

[0019] In one embodiment, the sound-absorbing layer (2) has a thickness of 0.2 g / cm 3 To 0.3g / cm 3 density and thickness from 2mm to 4mm.

[0020] In one embodiment, the medium-density sound insulation layer (3) comprises a polymer composite material, wherein the polymer composite material comprises polyvinyl chloride, chlorinated polyethylene or a combination thereof. The medium-density sound insulation layer has a Shore hardness of 60A to 80A, a hardness of 1.6 g / cm 3 To 1.9g / cm 3 density and thickness from 2mm to 4mm.

[0021] In one embodiment, the low-density sound-absorbing layer (4) contains synthetic fibers, and the synthetic fibers include glass fibers, polyester fibers, or a combination thereof. The low-density sound-absorbing layer (4) has a density of 0.3 g / cm 3 To 0.6g / cm 3 density and thickness from 15mm to 35mm.

[0022] In one embodiment, the flexible lightweight multilayer panel according to claim 1 has a total thickness ranging from 40 mm to 50 mm and a weight ranging from 40 kg / m 2 Up to 50kg / m 2 weight. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Embodiments of the present invention are described in more detail below with reference to the accompanying drawings, in which:

[0024] Figure 1 A sound insulation panel which is a lightweight building material according to an embodiment of the present invention;

[0025] Figure 2 A schematic diagram showing a multi-layer soundproofing panel according to an embodiment of the present invention; and

[0026] Figure 3 A schematic diagram showing a multi-layer sound insulation panel according to another embodiment of the present invention is shown. DETAILED DESCRIPTION

[0027] In the following description, a multi-layer soundproofing panel including sound-damping polyurethane foam and the like is described as a preferred example. It will be apparent to those skilled in the art that modifications, including additions and / or substitutions, may be made without departing from the scope and spirit of the invention. Certain details may be omitted so as not to obscure the invention; however, this disclosure is written to enable those skilled in the art to practice the teachings herein without conducting experiments.

[0028] The flexible soundproof panel of the present invention solves problems such as being heavy, thick and having a relatively low STC. It provides acceptable reduction of sound (e.g., a sound transmission class (STC) coefficient of at least 40 dB, preferably at least 45 dB) at a thickness of about 40 mm to 50 mm and a weight of about 46 kg / m2 to 47 kg / m2.

[0029] The present invention provides a flexible lightweight multi-layer panel for sound insulation applications in buildings, comprising at least two high-density sound insulation layers, at least two sound-absorbing layers, at least two medium-density sound-reflecting layers and at least one low-density sound-absorbing layer.

[0030] According to one embodiment of the present invention, the soundproofing panel is formed of seven layers, including: two high-density soundproofing layers (1); two sound-absorbing layers (2); two medium-density sound-reflecting layers (3); and a low-density sound-absorbing layer (4). However, it should be noted that the soundproofing panel of the present invention can also be constructed with more than seven layers without compromising its performance.

[0031] According to one embodiment of the present invention, when the sound insulation panel is formed of seven layers, the layers are arranged in the order of a high-density sound insulation layer, a sound-absorbing layer, a medium-density sound reflecting layer, a low-density sound absorbing layer, a medium-density sound reflecting layer, a sound-absorbing layer, and a high-density sound insulation layer.

[0032] According to another embodiment of the present invention, when the sound insulation panel is formed of seven layers, the layers are arranged in the order of a high-density sound insulation layer, a medium-density sound reflection layer, a sound absorbing layer, a low-density sound absorption layer, a sound absorbing layer, a medium-density sound reflection layer, and a high-density sound insulation layer.

[0033] According to one embodiment of the present invention, the high-density sound insulation layer (1) comprises a polymer composite material, wherein the polymer composite material comprises at least one of polyvinyl chloride and chlorinated polyethylene.

[0034] According to one embodiment of the present invention, the high-density sound insulation layer (1) has a Shore hardness of 40A to 60A, a hardness of 2.0 g / cm 3 To 2.3g / cm 3 density and 5mm to 6mm thickness.

[0035] According to one embodiment of the present invention, the sound-absorbing layer (2) is polyurethane foam ( Figure 1 ). The polyurethane foam comprises a first reaction composition (A side) and a second reaction composition (B side).

[0036] The A side contains at least one aromatic isocyanate component having an isocyanate functionality ranging from about 2 to about 2.5. The B side contains: A diol having a hydroxyl value of 380 to 480 mgKOH / g; A polyether polyol having a hydroxyl value of 140 to 330 mgKOH / g; A polymer polyol having a hydroxyl value of 20 to 30 mgKOH / g; catalyst; Foam stabilizers; and water.

[0037] According to one embodiment of the present invention, the glycol may be commercial brands of polypropylene glycol (PPG) and polyethylene glycol (PEG).

[0038] According to one embodiment of the present invention, the polyether polyol may be commercial brands MN-500, MN-700, MN1000, DL400 and T-403.

[0039] According to one embodiment of the present invention, the polymer polyol may be commercial brands POP36 / 28, POP93 / 28 and HPOP40.

[0040] According to one embodiment of the present invention, the first reaction composition (A side) and the second reaction composition (B side) are contacted at a stoichiometric ratio of NCO:OH functionality of 0.9:1 to 1.4:1, preferably at a stoichiometric ratio of NCO:OH functionality of 1.1:1 to 1.3:1.

[0041] In one aspect, the at least one aromatic isocyanate component can be an aromatic diol and a polyisocyanate, such as toluene-2,4-diisocyanate (TDI100) and toluene-2,6-diisocyanate and corresponding isomeric mixtures, diphenylmethane-4,4'-diisocyanate (MDI100), liquefied MDI (e.g., MDI100HL and MDI100LL), diphenylmethane-2,4'-diisocyanate, diphenylmethane-2,2'-diisocyanate and corresponding isomeric mixtures, diphenylmethane-4,4' and 2, 4'-diisocyanate (MDI50), a mixture of diphenylmethane 4,4'-, 2,4' and 2,2'-diisocyanate and liquefied MDI with toluene-2,4-diisocyanate (TDI100) and toluene-2,6-diisocyanate, polyphenyl polymethylene polyisocyanate (PMDI), a mixture of diphenylmethane 4,4'-, 2,4' and 2,2'-diisocyanate and liquefied MDI with polyphenyl polymethylene polyisocyanate (PMDI) and a mixture of PMDI with toluene diisocyanate.

[0042] According to one embodiment of the present invention, the diol is used to enhance the mechanical strength of the polyurethane foam, and its weight percentage accounts for 2% to 8% of the total weight of the multiple polyols. The polyether polyol is used to enhance the mechanical strength and adjust the glass transition temperature of the polyurethane foam, and its weight percentage accounts for 25% to 40% of the total weight of the multiple polyols. The polymer polyol is used to adjust the softness and glass transition temperature of the polyurethane foam, and its weight percentage accounts for 45% to 70% of the total weight of the multiple polyols.

[0043] According to one embodiment of the present invention, the sound-absorbing layer (2) has a thickness of 0.2 g / cm 3 To 0.3g / cm 3 density and thickness from 2mm to 4mm.

[0044] According to one embodiment of the present invention, the catalyst can be selected from tertiary amines and organic tin compounds, such as triethylamine, dimethylcyclohexylamine, N-methylmorpholine, N,N′-dimethylpiperazine, 2-(dimethylaminoethoxy)ethanol, diazabicyclo[2.2.2]octane, bis(2-dimethylaminoethyl)ether (A1), 1,4-diazabicyclo[2.2.2]octane (A33), tin diacetate, tin dioctoate, tin dilaurate or dialkyl derivatives of dialkyl tin salts of aliphatic carboxylic acids, such as dibutyltin diacetate and dibutyltin dilaurate (DBTDL).

[0045] According to one embodiment of the present invention, the foam stabilizer may be TEGOSTAB from Evonik, Covestro DESMODUR and DESMOPHEN from Covestro, VORASRF from Dow, and JEFFADD from Huntsman.

[0046] According to one embodiment of the present invention, the medium-density sound insulation layer (3) contains a polymer composite material, and the polymer composite material includes at least one of polyvinyl chloride and chlorinated polyethylene.

[0047] According to one embodiment of the present invention, the medium-density sound insulation layer (3) has a Shore hardness of 60A to 80A, a hardness of 1.6 g / cm 3 To 1.9g / cm 3 density and thickness from 2mm to 4mm.

[0048] According to one embodiment of the present invention, the low-density sound absorbing layer (4) contains synthetic fibers, and the synthetic fibers include at least one of glass fibers and polyester fibers.

[0049] According to one embodiment of the present invention, the low-density sound-absorbing layer (4) has a density of 0.3 g / cm 3 To 0.6g / cm 3 density and thickness from 15mm to 35mm.

[0050] Examples

[0051] Example 1

[0052] In this example, a soundproof panel having five layers is provided. The five layers contain two high-density soundproof layers (1); two medium-density sound-reflecting layers (2); and one low-density sound-absorbing layer (3). The layers are arranged in the order of high-density soundproof layer (1), medium-density sound-reflecting layer (2), low-density sound-absorbing layer (3), medium-density sound-reflecting layer (2), and high-density soundproof layer (1). Table 1 shows the properties of a 1 square meter soundproof panel.

[0053] Table 1 Sound insulation panels index Thickness(mm) 40 <![CDATA[Weight (kg / m 2 )]]> 46.5 <![CDATA[Sound insulation STC (1) > 38

[0054] (1) Evaluate the sound transmission class (STC) according to ASTM E90.

[0055] Example 2

[0056] In this example, a soundproofing panel having seven layers is provided. The seven layers include two high-density soundproofing layers (1); two sound-absorbing layers (2); two medium-density sound-reflecting layers (3); and one low-density sound-absorbing layer (4). Figure 2, the layers are arranged in sequence, wherein the layers are arranged in the order of a high-density sound insulation layer (1), a sound-absorbing layer (2), a medium-density sound reflection layer (3), a low-density sound absorption layer (4), a medium-density sound reflection layer (3), a sound-absorbing layer (2) and a high-density sound insulation layer (1).

[0057] The formulations of the first and second parts of the sound dampening PU foam are presented in Table 2a and Table 2b, respectively.

[0058] Table 2a Ingredients in Part A Phr MDI100LL 50 TDI80 50

[0059] Table 2b

[0060] Table 3 shows the properties of 1 square meter of sound insulation panel.

[0061] Table 3 Sound insulation panels index Thickness(mm) 40 <![CDATA[Weight (kg / m 2 )]]> 47.7 <![CDATA[Sound insulation STC (1) > 47

[0062] (1) Evaluate the sound transmission class (STC) according to ASTM E90.

[0063] Example 3

[0064] In this example, a soundproofing panel having seven layers is provided. The seven layers include two high-density soundproofing layers (1); two sound-absorbing layers (2); two medium-density sound-reflecting layers (3); and one low-density sound-absorbing layer (4). Figure 3 The layers are arranged in the order of a high-density sound insulation layer (1), a medium-density sound reflection layer (3), a sound-absorbing layer (2), a low-density sound absorption layer (4), a sound-absorbing layer (2), a medium-density sound reflection layer (3) and a high-density sound insulation layer (1).

[0065] The formulations of the first and second parts of the sound dampening PU foam are presented in Table 4a and Table 4b, respectively.

[0066] Table 4a Ingredients in Part A Phr MDI100LL 50 TDI80 50

[0067] Table 4b Ingredients in Part B Phr Role DPG 6 Diol DL400 35 Polyether polyols POP93 / 28 65 Polymer polyols 8002 0.3 Foam stabilizer DBTDL 0.3 catalyst A1 0.5 catalyst <![CDATA[H2O]]> 0.6 Foaming agent

[0068] Table 5 shows the properties of 1 square meter of sound insulation panel.

[0069] Table 5

[0070] (1) Evaluate the sound transmission class (STC) according to ASTM E90.

[0071] The foregoing description of the present invention has been provided for the purpose of illustration and description. The present invention is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations will be apparent to those skilled in the art.

[0072] The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, thereby enabling others skilled in the art to understand the invention for various embodiments and with various modifications as are suited to the particular use contemplated.

[0073] definition

[0074] Throughout this specification, unless otherwise specified herein, the word "comprise" or variations such as "comprises" or "comprising" should be understood to imply the inclusion of the stated integer or group of integers, but not the exclusion of any other integer or group of integers. It should also be noted that in this disclosure and particularly in the claims and / or paragraphs, terms such as "comprises / comprised / comprising" may have the meanings ascribed to them in U.S. patent law; for example, they allow for non-explicit recitation of elements but exclude elements that exist in the prior art or that affect the basic or novel characteristics of the invention.

[0075] Throughout the present specification and claims, unless otherwise indicated herein, the word "include" or variations such as "includes" or "including", will be understood to imply the inclusion of a stated integer or groups of integers but not the exclusion of any other integer or groups of integers.

[0076] References in this specification to "one embodiment", "an exemplary embodiment", etc. indicate that the described embodiment may include certain features, structures, or characteristics, but each embodiment may not necessarily include the certain features, structures, or characteristics. Moreover, such phrases do not necessarily refer to the same embodiment. In addition, when a certain feature, structure, or characteristic is described in conjunction with an embodiment, it should be understood that it is within the knowledge of a technician in the field to affect such features, structures, or characteristics in conjunction with other embodiments, whether or not explicitly described.

[0077] Other definitions of selected terms used herein may be considered within the specific embodiments of the present invention and are applied throughout the specific embodiments of the present invention. Unless otherwise defined, all other technical terms used herein have the same meanings as those generally understood by those skilled in the art to which the present invention belongs.

[0078] Those skilled in the art will appreciate that, in light of these teachings, alternative embodiments may be implemented without undue experimentation or departure from the spirit or scope of the invention as set forth in the appended claims. The present invention is limited solely by the appended claims, which encompass all such embodiments and modifications when viewed in conjunction with the above description and drawings.

Claims

1. A flexible, lightweight, multilayer panel for sound insulation applications in buildings, comprising: At least two high-density sound insulation layers; At least two sound-absorbing layers; At least two medium-density sound-reflecting layers; as well as at least one low-density sound-absorbing layer, The flexible lightweight multilayer panel has a sound transmission class (STC) of at least 40 dB according to ASTM E90.

2. The flexible lightweight multi-layer panel according to claim 1, wherein the layers are arranged in the order of a high-density sound insulation layer, a sound-absorbing layer, a medium-density sound reflection layer, a low-density sound absorption layer, a medium-density sound reflection layer, a sound-absorbing layer, and a high-density sound insulation layer.

3. The flexible lightweight multi-layer panel according to claim 1, wherein the layers are arranged in the order of a high-density sound insulation layer, a medium-density sound reflection layer, a sound-absorbing layer, a low-density sound absorption layer, a sound-absorbing layer, a medium-density sound reflection layer, and a high-density sound insulation layer.

4. The flexible lightweight multi-layer panel according to claim 1, wherein the high-density sound insulation layer comprises a polymer composite material, and the polymer composite material comprises polyvinyl chloride, chlorinated polyethylene or a combination thereof.

5. The flexible lightweight multi-layer panel according to claim 1, wherein the high-density sound insulation layer has a Shore hardness of 40A to 60A, a hardness of 2.0 g / cm 3 To 2.3g / cm 3 density and 5mm to 6mm thickness.

6. The flexible lightweight multi-layer panel of claim 1, wherein the sound dampening layer comprises polyurethane foam.

7. The flexible lightweight multilayer panel according to claim 6, wherein the polyurethane foam comprises: A first reaction composition comprising at least one aromatic isocyanate component having an isocyanate functionality ranging from about 2 to about 2.5; as well as A second reaction composition comprising: A diol having a hydroxyl value of 380 to 480 mgKOH / g; A polyether polyol having a hydroxyl value of 140 to 330 mgKOH / g; A polymer polyol having a hydroxyl value of 20 to 30 mgKOH / g; catalyst; Foam stabilizers; and water.

8. The flexible lightweight multi-layer panel of claim 7, wherein the first reactive composition and the second reactive composition are contacted at a stoichiometric ratio of NCO:OH functionality of 0.9:1 to 1.4:

1.

9. The flexible lightweight multi-layer panel of claim 8, wherein the first reactive composition and the second reactive composition are contacted at a stoichiometric ratio of NCO:OH functionality of 1.1:1 to 1.3:

1.

10. The flexible lightweight multi-layer panel according to claim 7, wherein the at least one aromatic isocyanate component comprises an aromatic diol and a polyisocyanate.

11. The flexible lightweight multi-layer panel according to claim 7, wherein the diol is used to enhance the mechanical strength of the polyurethane foam and constitutes a weight percentage ranging from 2% to 8% in the total weight of the plurality of polyols.

12. The flexible lightweight multi-layer panel according to claim 7, wherein the polyether polyol is used to enhance mechanical strength and adjust the glass transition temperature of the polyurethane foam, and constitutes 25 to 40 weight percent in the total weight of the plurality of polyols.

13. The flexible lightweight multi-layer panel according to claim 7, wherein the polymer polyol is used to adjust the softness and glass transition temperature of the polyurethane foam and constitutes 45 to 70 weight percent in the total weight of the plurality of polyols.

14. The flexible lightweight multi-layer panel according to claim 1, wherein the sound absorbing layer has a strength of 0.2 g / cm 3 To 0.3g / cm 3 density and thickness from 2mm to 4mm.

15. The flexible lightweight multi-layer panel of claim 1, wherein the medium density sound insulation layer comprises a polymer composite material comprising polyvinyl chloride, chlorinated polyethylene, or a combination thereof.

16. The flexible lightweight multi-layer panel according to claim 1, wherein the medium-density sound insulation layer has a Shore hardness of 60A to 80A, a hardness of 1.6 g / cm 3 To 1.9g / cm 3 density and thickness from 2mm to 4mm.

17. The flexible lightweight multi-layer panel of claim 1, wherein the low-density sound absorbing layer comprises synthetic fibers, the synthetic fibers comprising glass fibers, polyester fibers, or a combination thereof.

18. The flexible lightweight multi-layer panel according to claim 1, wherein the low-density sound absorbing layer has a density of 0.3 g / cm 3 To 0.6g / cm 3 density and thickness from 15mm to 35mm.

19. The flexible lightweight multilayer panel according to claim 1, wherein the flexible lightweight multilayer panel has a total thickness ranging from 40 mm to 50 mm, and a weight ranging from 40 kg / m 2 Up to 50kg / m 2 weight.

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