Sound-absorbing material and preparation method thereof

Abstract

The present invention provides a sound-absorbing material and a preparation method thereof, belonging to the technical field of sound insulation materials. The preparation method comprises: uniformly mixing 63-70 parts of α-type high-strength gypsum, 25-30 parts of hollow polysilicon, 1-2 parts of fiber, 1-5 parts of fly ash, and 1-3 parts of an additive, adding water and stirring to form a slurry, injecting the slurry into a mold, and demolding after initial and final setting. The slurry is then placed in an environment with a humidity greater than 90% for further hydration, and finally dried to a moisture content of less than 5% to obtain the sound-absorbing material. The present invention uses gypsum as the main cementitious material and combines it with a hollow polysilicon structural design. The material has the characteristics of sound absorption and noise reduction, fire retardancy, light mass density, high compressive strength, low water absorption, and environmental friendliness. It is suitable for lime, gypsum, and cement-based products.

Description

Technical Field

[0001] The present invention belongs to the technical field of sound insulation materials, and in particular relates to a sound absorbing material and a preparation method thereof. Background Art

[0002] Noise is a systemic phenomenon that harms the human body, causing changes in both the auditory system and non-auditory systems. While these effects are primarily physiological in the early stages, long-term exposure to relatively strong noise can lead to pathological changes.

[0003] At present, the sound-absorbing materials on the market mainly include: 1. Porous sound-absorbing materials, such as rock wool, glass wool, slag wool, polyester fiberboard, foam plastic, etc.; 2. Resonant sound-absorbing materials, such as perforated plates (metal, wood, gypsum board) + cavity, thin film resonance structure (PVC film / canvas + cavity), etc.; 3. Composite sound-absorbing materials, such as gradient pore materials (such as gradient foam), micro-perforated plates + porous filling layers, etc.; 4. Fiber-reinforced sound-absorbing materials, such as carbon fiber sound-absorbing panels, basalt fiber composites, ceramic fiberboards, etc.

[0004] Among them, commonly used sound absorption and sound insulation materials usually have poor fire resistance, weather resistance, strength, sound absorption and sound insulation performance, and expose the following various problems when used: (1) For example, high-performance materials (such as polyester fiber, acoustic foam) and customized structures are expensive, and the complex manufacturing process may further increase the price. (2) They are not friendly to small spaces (such as small recording studios and home theaters). To achieve the ideal effect, the material needs to be of a certain thickness and takes up a lot of space. (3) Insufficient durability and easy aging: For example, foam materials are prone to decomposition or mold under high temperature and high humidity. (4) Structural damage: Collision or pressure can easily cause deformation, affecting performance. (5) Chemical stability: Some materials may release volatile organic compounds (VOCs). (6) Frequency limitation: The absorption effect on low frequencies is weak, and low-frequency traps or resonant structures are often required, which increases the design complexity.

[0005] In view of this, the present invention is proposed. Summary of the Invention

[0006] The purpose of the present invention is to provide a sound-absorbing material and a preparation method thereof, which uses gypsum as the main cementitious material and is combined with a hollow polysilicon material structure design. The sound-absorbing material has the characteristics of sound absorption and noise reduction, fire retardancy, light mass density, high compressive strength, low water absorption, and environmental protection. It is suitable for lime, gypsum and cement-based products.

[0007] In order to achieve the above objectives, the present invention adopts the following technical solutions:

[0008] In a first aspect, the present invention provides a method for preparing a sound-absorbing material. In parts by mass, 63-70 parts of α-type high-strength gypsum, 25-30 parts of hollow polysilicon, 1-2 parts of fiber, 1-5 parts of fly ash, and 1-3 parts of an additive are uniformly mixed, water is added, and stirred to form a slurry. The slurry is injected into a mold, and after initial and final setting, the mold is removed. The material is then placed in an environment with a humidity greater than 90% for further hydration, and finally dried to a moisture content of less than 5% to obtain the sound-absorbing material.

[0009] Furthermore, the preparation method of the hollow polysilicon material includes: mixing 20-50 parts of quartz sand, 10-30 parts of cullet, 10-15 parts of Al2O3, 7-10 parts of Na2O, 5-8 parts of CaCO3 and 10-20 parts of potassium feldspar in parts by mass, adding 0.5-1 part of Li2O as a nucleating agent, continuing to stir to form balls, controlling the particle size range to be 0.1mm-5mm, sintering the balled material at 1000-1150°C and keeping it warm for 0.5-3h to obtain a silicon material with a hollow polysilicon structure, and screening to obtain materials with three particle sizes of 0.1-0.5mm, 0.5-2mm and 2-5mm.

[0010] Among them, CaCO3 and potassium feldspar act as pore formers.

[0011] Furthermore, the bulk density of the three particle sizes is 400-450 kg / m 3 、320-350kg / m 3 and 60-300kg / m 3 .

[0012] Preferably, the cylinder pressure strength of the materials with the three particle sizes is greater than 3 MPa.

[0013] Preferably, when the hollow polysilicon material is added as a raw material, the mass ratio of the three particle sizes of 0.1-0.5 mm, 0.5-2 mm, and 2-5 mm is 45-49: 45-49: 2-10.

[0014] Matching the three types of particle sizes can better ensure that low, medium and high frequency noises can be absorbed.

[0015] Furthermore, the additives include a hydrophobic agent, a water reducing agent and a coagulant.

[0016] Furthermore, the mass ratio of the hydrophobic agent, the water reducing agent and the coagulant is 1: 0.5-5: 0.5-5.

[0017] Optionally, the hydrophobic agent includes one or more of silane, silicone emulsion or calcium stearate.

[0018] Optionally, the water reducer includes one or more of sodium lignin sulfonate, calcium lignin sulfonate, β-naphthalene sulfonate formaldehyde condensate, methyl allyl polyoxyethylene ether or allyl polyoxyethylene ether.

[0019] Optionally, the coagulant comprises potassium sulfate and / or sodium citrate.

[0020] Optionally, the fibers include one or more of glass fibers, polypropylene fibers, or plant fibers, which can increase the strength of the sound-absorbing material.

[0021] Preferably, the particle size of the fly ash is controlled to be no less than 325 mesh.

[0022] Furthermore, the drying is carried out at 40-50°C.

[0023] In a second aspect, the present invention further provides a sound absorbing material, which is prepared by the above-mentioned preparation method.

[0024] Compared with the existing technology, the present invention prepares hollow polysilicon materials by making pores, and divides the hollow polysilicon materials into three particle sizes for matching. After being mixed with cementitious materials to form sound-absorbing materials, the materials can absorb various noises such as low, medium and high frequencies, thereby having the characteristics of sound absorption and noise reduction, fire retardancy, light mass density, high compressive strength, low water absorption, and environmental protection. It is suitable for lime, gypsum and cement-based products. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the specific embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0026] Figure 1 This is a macroscopic photograph of the hollow polysilicon material with a particle size of 0.1-0.5 mm according to Example 1 of the present invention;

[0027] Figure 2 This is a macroscopic photograph of the hollow polysilicon material with a particle size of 0.5-2 mm according to Example 1 of the present invention;

[0028] Figure 3 This is a macroscopic photograph of the hollow polysilicon material with a particle size of 2-5 mm according to Example 1 of the present invention;

[0029] Figure 4 This is a macroscopic photograph of the sound-absorbing material plate of Example 1 of the present invention. DETAILED DESCRIPTION

[0030] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts shall fall within the scope of protection of the present invention.

[0031] Example 1

[0032] A method for preparing a sound-absorbing material:

[0033] (1) According to the mass ratio, 20 parts of quartz sand, 30 parts of cullet, 15 parts of Al2O3, 7 parts of Na2O, 8 parts of CaCO3 and 20 parts of potassium feldspar were vigorously mixed in a high-speed mixer for 1 hour. 1 part of Li2O nucleating agent was added to the mixed material and the mixture was stirred for 20 minutes to form balls. The particle size range was controlled to be 0.1mm-5mm. The balled material was sintered in a box furnace at 1000℃ and kept warm for 3 hours to obtain a silicon material with a hollow structure. The sieves obtained 0.1-0.5mm, 0.5-2mm and 2-5mm, respectively. Figure 1-3 As shown, its bulk density is 450kg / m 3 、350kg / m 3 and 300kg / m 3 , its compressive strength is 3.2MPa.

[0034] (2) According to parts by mass, 64 parts of α-type high-strength gypsum, 27 parts of the hollow polysilicon material obtained in step (1), 2 parts of glass fiber, 5 parts of 325-mesh fly ash, and 2 parts of additives were uniformly mixed to obtain a mixture. The hollow polysilicon material had a single particle size of 0.1-0.5 mm; and the additives were calcium stearate, methyl allyl polyoxyethylene ether, and potassium sulfate in a mass ratio of 1:0.5:0.5.

[0035] (3) Add the mixture obtained in step (2) to water accounting for 45% of the mass of the mixture, and stir it at 350 rpm for 3 minutes using a stirrer to promote uniform hydration. Pour the slurry into the mold, slightly vibrate to remove bubbles or vacuum degas, and demould after 15 minutes of initial setting and 40 minutes of final setting. After demoulding, place it in an environment with a humidity greater than 90% and let it stand for 24 hours to promote complete hydration of the remaining hemihydrate gypsum, and dry it at 45°C to a moisture content of less than 5% to obtain the sound-absorbing material, whose macroscopic morphology is as follows: Figure 4 In addition, its test performance is shown in Table 1, and its low, medium and high frequency noise reduction performance is shown in Table 2.

[0036] Example 2

[0037] The difference from Example 1 is that in step (2), the hollow polysilicon material is a mixture of two particle sizes of 0.1-0.5 mm and 0.5-2 mm in a mass ratio of 1:1.

[0038] The test performance is shown in Table 1, and the low, medium and high frequency noise reduction performance is shown in Table 2.

[0039] Example 3

[0040] The difference from Example 1 is that in step (2), the hollow polysilicon material is a mixture of three particle sizes of 0.1-0.5 mm, 0.5-2 mm and 2-5 mm in a mass ratio of 49:49:2.

[0041] The test performance is shown in Table 1, and the low, medium and high frequency noise reduction performance is shown in Table 2.

[0042] Example 4

[0043] A method for preparing a sound-absorbing material:

[0044] (1) According to the mass ratio, 40 parts of quartz sand, 20 parts of cullet, 10 parts of Al2O3, 10 parts of Na2O, 5 parts of CaCO3 and 15 parts of potassium feldspar were vigorously mixed in a high-speed mixer for 1 hour. 0.5 parts of Li2O nucleating agent was added to the mixed material and the mixture was stirred for 20 minutes to form balls. The particle size range was controlled to be 0.1mm-5mm. The balled material was sintered in a box furnace at 1150℃ and kept warm for 0.5 hours to obtain a silicon material with a hollow structure. The sieves obtained particles of 0.1-0.5mm, 0.5-2mm and 2-5mm. The bulk density was 400kg / m 3 、320kg / m 3 and 80kg / m 3 , its compressive strength is 3.0MPa.

[0045] (2) According to parts by mass, 63 parts of α-type high-strength gypsum, 30 parts of the hollow polysilicon material obtained in step (1), 1 part of glass fiber, 4 parts of 325-mesh fly ash, and 2 parts of additives are uniformly mixed to obtain a mixture. The hollow polysilicon material has two particle sizes of 0.1-0.5 mm and 0.5-2 mm in a mass ratio of 1:1; the additives are silane, β-naphthalenesulfonate formaldehyde condensate, and sodium citrate in a mass ratio of 1.2:0.3:0.5.

[0046] (3) The mixture obtained in step (2) is added to water accounting for 50% of the mass of the mixture, and stirred at 350 rpm for 4 minutes using a stirrer to promote uniform hydration. The slurry is injected into the mold, slightly vibrated to remove bubbles or vacuum degassing, and demolded after 15 minutes of initial setting and 50 minutes of final setting. After demolding, it is placed in an environment with a humidity greater than 90% and allowed to stand for 28 hours to promote complete hydration of the remaining hemihydrate gypsum, and then dried at 40°C to a moisture content of less than 5% to obtain the sound-absorbing material. Its test performance is shown in Table 1.

[0047] Example 5

[0048] A method for preparing a sound-absorbing material:

[0049] (1) According to the mass ratio, 50 parts of quartz sand, 10 parts of broken glass, 12 parts of Al2O3, 8 parts of Na2O, 6 parts of CaCO3 and 14 parts of potassium feldspar were vigorously mixed in a high-speed mixer for 1 hour. 0.8 parts of Li2O nucleating agent was added to the mixed material and the mixture was stirred for 20 minutes to form balls. The particle size range was controlled to be 0.1mm-5mm. The balled material was sintered in a box furnace at 1100℃ and kept warm for 1 hour to obtain a silicon material with a hollow structure. The particles were sieved to obtain 0.1-0.5mm, 0.5-2mm and 2-5mm. The bulk density was 420kg / m 3 、330kg / m 3 and 130kg / m 3 , its compressive strength is 3.1MPa.

[0050] (2) According to parts by mass, 70 parts of α-type high-strength gypsum, 25 parts of the hollow polysilicon material obtained in step (1), 1.5 parts of glass fiber, 1.5 parts of 325-mesh fly ash, and 2 parts of additives are uniformly mixed to obtain a mixture. The hollow polysilicon material has three particle sizes of 0.1-0.5 mm, 0.5-2 mm, and 2-5 mm in a mass ratio of 48:48:4; the additives are calcium stearate, methyl allyl polyoxyethylene ether, and potassium sulfate in a mass ratio of 1:0.5:0.5.

[0051] (3) The mixture obtained in step (2) is added to water accounting for 50% of the mass of the mixture, and stirred at a speed of 350 rpm for 5 minutes using a stirrer to promote uniform hydration. The slurry is injected into the mold, slightly vibrated to remove bubbles or vacuum degassing, and demolded after 15 minutes of initial setting and 30 minutes of final setting. After demolding, it is placed in an environment with a humidity greater than 90% and allowed to stand for 30 hours to promote complete hydration of the remaining hemihydrate gypsum, and then dried at 50°C to a moisture content of less than 5% to obtain the sound-absorbing material. Its test performance is shown in Table 1.

[0052] Comparative Example 1

[0053] The difference from Example 3 is that in step (2), the hollow polysilicon material is a mixture of three particle sizes of 0.1-0.5 mm, 0.5-2 mm and 2-5 mm in a mass ratio of 40:40:20.

[0054] The test performance is shown in Table 1.

[0055] Comparative Example 2

[0056] The difference from Example 3 is that in step (3), the drying temperature is 60°C.

[0057] The test performance is shown in Table 1.

[0058] Table 1 Comparison of properties of the sound absorbing materials obtained in Examples 1-5 and Comparative Examples 1-2

[0059]

[0060] Table 2 Comparison of noise reduction performance of the sound absorbing materials obtained in Examples 1-3 for low, medium and high frequencies

[0061]

[0062] From Table 1, when the hollow polysilicon material in Comparative Example 1 is a combination of the three particle sizes but the ratio is not appropriate, its sound absorption effect is lower than that of Example 3. When the drying temperature in Comparative Example 2 is too high, the compressive strength will decrease.

[0063] It can be seen from Table 2 that when the hollow polysilicon material is a combination of the three particle sizes and the proportions are appropriate, its sound absorption and noise reduction performance are excellent and the compressive strength meets the requirements; when the hollow polysilicon material in Example 2 is a combination of the two particle sizes, its absorption of low-frequency noise is slightly poor; when the hollow polysilicon material in Example 1 is a single particle size, its absorption of medium and low-frequency noise is also slightly poor accordingly.

[0064] Please note that the technical features of the above embodiments can be combined arbitrarily. In order to make the description concise, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification. The above embodiments only express several implementation methods of the present application. The description is relatively specific and detailed, but it cannot be understood as a limitation on the scope of the invention patent. It should be pointed out that for ordinary technicians in this field, without departing from the concept of this application, several variations and improvements can be made, which all fall within the scope of protection of this application. Therefore, the scope of protection of the patent in this application shall be based on the attached claims.

Claims

1. A method for preparing a sound-absorbing material, characterized in that: According to parts by mass, 63-70 parts of α-type high-strength gypsum, 25-30 parts of hollow polysilicon material, 1-2 parts of fiber, 1-5 parts of fly ash and 1-3 parts of additives are uniformly mixed, water is added and stirred to form a slurry, the slurry is injected into a mold, and demolded after initial and final setting, and then placed in an environment with a humidity greater than 90% for further hydration, and finally dried to a moisture content of less than 5% to obtain the sound absorbing material; The hollow polysilicon material includes three particle sizes of 0.1-0.5mm, 0.5-2mm, and 2-5mm, and the mass ratio thereof is 45-49: 45-49: 2-10; The drying is carried out at 40-50°C; The preparation method of the hollow polysilicon material comprises: mixing 20-50 parts by mass of quartz sand, 10-30 parts by mass of cullet, 10-15 parts by mass of Al2O3, 7-10 parts by mass of Na2O, 5-8 parts by mass of CaCO3, and 10-20 parts by mass of potassium feldspar, adding 0.5-1 parts by mass of Li2O as a nucleating agent, continuing to stir to form balls, controlling the particle size range to be 0.1-5 mm, sintering the balled material at 1000-1150° C. and keeping the temperature for 0.5-3 hours to obtain a hollow polysilicon material, and screening to obtain materials with three particle sizes of 0.1-0.5 mm, 0.5-2 mm, and 2-5 mm. The bulk density of the three particle sizes is 400-450 kg / m 3 、320-350kg / m 3 and 60-300kg / m 3 ; The cylinder pressure strength of the materials with the three particle sizes is all greater than 3MPa.

2. The preparation method according to claim 1, characterized in that The additives include water repellent, water reducing agent and coagulant; The mass ratio of the hydrophobic agent, water reducing agent and coagulant is 1: 0.5-5: 0.5-5.

3. The preparation method according to claim 2, characterized in that The hydrophobic agent includes one or more of silane, silicone emulsion or calcium stearate; and / or, the water reducing agent comprises one or more of sodium lignin sulfonate, calcium lignin sulfonate or β-naphthalenesulfonate formaldehyde condensate; And / or, the coagulant comprises potassium sulfate.

4. The preparation method according to claim 1, characterized in that The fibers include one or more of glass fibers, polypropylene fibers or plant fibers.

5. The preparation method according to claim 1, characterized in that The particle size of the fly ash is controlled to be no less than 325 meshes.

6. A sound absorbing material, characterized in that: The method is prepared according to any one of claims 1 to 5.

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