A novel sound-insulating decorative panel and its preparation method

Abstract

This invention relates to the field of building materials technology, specifically to a novel sound-insulating decorative panel and its preparation method. This invention overcomes the shortcomings of existing sound-insulating decorative panels, such as poor sound insulation performance and poor durability. The novel sound-insulating decorative panel of this invention consists of four layers, from top to bottom: a decorative layer, a sound-absorbing layer, a sound-insulating layer, and a backing layer. The raw materials for preparing the sound-absorbing layer include: modified castor oil-based polyol, triethylenediamine catalyst, silicone oil foam stabilizer, epoxy-modified silica, epoxidized soybean oil, and diphenylmethane diisocyanate. The raw materials for preparing the sound-insulating layer include: gypsum powder, cement, blast furnace slag powder, fly ash, barite powder, fumed nano-silica, polycarboxylate superplasticizer, citric acid retarder, modified glass fiber, and silicone oil emulsion waterproofing agent. Finally, the novel sound-insulating decorative panel, prepared using a double-modified adhesive, exhibits excellent sound insulation performance and strong durability, making it suitable for long-term application in residential or office areas.

Description

Technical Field

[0001] This invention relates to the field of building materials technology, specifically to a novel sound-insulating decorative panel and its preparation method. Background Technology

[0002] In modern society, noise pollution has become a significant factor affecting people's quality of life and work. Long-term exposure to noise can not only interfere with people's normal rest and study, leading to decreased sleep quality and difficulty concentrating, but may also damage hearing and cause a series of health problems such as tinnitus and high blood pressure, seriously affecting physical and mental health.

[0003] To reduce noise in buildings, various methods have been adopted. Installing double or multi-pane windows, using an air gap to block sound transmission, can effectively reduce noise from outside traffic and other sources entering the room; laying sound-absorbing carpets, with their porous structure, can absorb some sound energy, reduce indoor sound reflection, and improve the acoustic environment; using sound-insulating decorative panels is also a common method, as it can directly block and absorb sound, improving indoor sound insulation.

[0004] Soundproof decorative panels are widely used in residential, commercial, and industrial buildings. They offer numerous advantages, including effective sound insulation and noise reduction, excellent decorative properties that beautify interior spaces, and convenient installation that improves construction efficiency.

[0005] Compared to ordinary soundproofing panels, multi-layer soundproofing panels offer superior sound insulation and structural stability. They enhance sound insulation through the combination of multiple layers of different materials, leveraging the interactions between these materials to further improve soundproofing performance, making them particularly effective in environments with extremely high sound insulation requirements. However, existing multi-layer soundproofing panels have drawbacks when used in general residential and office spaces. Firstly, their sound insulation performance still needs improvement, failing to fully meet people's demands for a quiet environment, especially regarding high-frequency noise blocking. Secondly, their durability is relatively poor; long-term use can lead to deformation and delamination, affecting sound insulation performance and lifespan, requiring frequent maintenance or replacement, increasing both operating and time costs.

[0006] Therefore, developing multi-layer sound-insulating decorative panels that combine high-efficiency sound insulation performance with excellent durability remains an important direction that the industry needs to continuously explore and break through.

[0007] To address this, a novel sound-insulating decorative panel and its preparation method are proposed. Summary of the Invention

[0008] The purpose of this invention is to provide a novel sound-insulating decorative panel and its preparation method. The novel sound-insulating decorative panel of this invention consists of four layers, from top to bottom: a decorative layer, a sound-absorbing layer, a sound-insulating layer, and a backing layer. The raw materials for preparing the sound-absorbing layer include: modified castor oil-based polyol, triethylenediamine catalyst, silicone oil foam stabilizer, epoxy-modified silica, epoxidized soybean oil, and diphenylmethane diisocyanate. The raw materials for preparing the sound-insulating layer include: gypsum powder, cement, blast furnace slag powder, fly ash, barite powder, fumed nano-silica, polycarboxylate superplasticizer, citric acid retarder, modified glass fiber, and silicone oil emulsion waterproofing agent. The novel sound-insulating decorative panel, finally prepared using a double-modified adhesive, exhibits good sound insulation performance and strong durability, making it suitable for long-term application in residential or office areas.

[0009] To achieve the above objectives, the present invention provides the following technical solution:

[0010] On one hand, the present invention provides a novel sound-insulating decorative panel, which consists of four layers: a decorative layer, a sound-absorbing layer, a sound-insulating layer, and a backing layer; wherein, by weight,

[0011] The raw materials for preparing the decorative layer include: wood flour, polyvinyl chloride resin, composite lead hot salt stabilizer, stearic acid, and KH-550.

[0012] The raw materials for preparing the sound-absorbing layer include: 100 parts of modified castor oil-based polyol, 1 part of triethylenediamine, 2 parts of silicone oil foam stabilizer, 5-9 parts of epoxy-modified silica, 2 parts of epoxidized soybean oil, and diphenylmethane diisocyanate.

[0013] The raw materials for preparing the sound insulation layer include: 40-50 parts gypsum powder, 4-6 parts cement, 16-20 parts blast furnace slag powder, 6-10 parts fly ash, 30-35 parts barite powder, 5 parts fumed nano silica, 1 part polycarboxylate superplasticizer, 0.5 parts citric acid retarder, 6-10 parts modified glass fiber, and 1 part silicone oil emulsion waterproofing agent.

[0014] The back panel is made of commercially available 5mm multi-layer plywood.

[0015] Preferably, the cement is low-alkalinity sulfoaluminate cement; the blast furnace slag powder has a particle size of 400 mesh.

[0016] On the other hand, the present invention provides a method for preparing a novel sound-insulating decorative panel. The method for preparing the novel sound-insulating decorative panel is as follows: a double-modified epoxy adhesive is coated on the surface of the backing layer, and the wet weight coating amount is controlled at 120-150 g / m². 2The sound insulation layer is placed on the backing layer coated with adhesive and pressed lightly to adhere it. Then, the sound absorption layer and the decorative layer are applied in sequence with the same amount of coating to obtain the assembled panel. The assembled panel is then hot-pressed and laminated at a temperature of 50-60℃, a pressure of 0.3-0.5MPa, and a hot-pressing time of 2 hours. After the pressed product is trimmed, it is cured for 72 hours to obtain a new type of sound insulation decorative panel.

[0017] Preferably, the preparation method of the dual-modified epoxy adhesive is as follows: 100 parts of modified epoxy resin are added to a reaction vessel and stirred at 150 rpm. First, nano-silica dispersion is added and stirring is continued for 20 min. Then, 3-7 parts of ethylene glycol butyl ether, 1-2 parts of KH-560, 0.3-0.7 parts of waterborne polyurethane, 0.2-0.4 parts of dispersant, 0.1-0.2 parts of defoamer, and 0.1-0.2 parts of mildew inhibitor are added to the reaction vessel in sequence. After each component is added, stirring is continued for 10 min to obtain a mixed system. 40-50 parts of active amine curing agent are added to the mixed system and stirring is continued for 30 min. Then, the mixture is allowed to stand for defoaming for 20 min to obtain the dual-modified epoxy adhesive.

[0018] Preferably, the aqueous epoxy resin emulsion is preheated at 60°C for 30 minutes, and polytetrahydrofuran ether diol is vacuum dehydrated at 80°C for 1 hour and then added to the aqueous epoxy resin emulsion. The mixture is then reacted at 70°C for 2 hours. After the reaction is completed, the mixture is cooled to about 50°C, and fatty alcohol polyoxyethylene ether is added. The mixture is then stirred for another 30 minutes to obtain the modified epoxy resin.

[0019] Preferably, the water-based amine curing agent is poured into a clean reaction vessel, and triethylenetetramine reactive diluent is slowly added dropwise over 10 minutes while stirring. After the addition is complete, stirring is continued for 20 minutes. Then, salicylic acid and alkylphenol polyoxyethylene ether phosphate are added sequentially, and stirring is continued for 30 minutes to obtain the reactive amine curing agent.

[0020] Preferably, the sound-absorbing layer is prepared as follows: 5-7 parts of epoxy-modified silica are added to 100 parts of modified castor oil-based polyol and dispersed at high speed for 30 minutes to obtain a dispersion slurry. Then, 2-3 parts of deionized water, 0.5-1 parts of triethylenediamine catalyst, 0.5-1 parts of silicone oil foam stabilizer, and 1-3 parts of epoxidized soybean oil are added to the dispersion slurry and mixed for 3 minutes. Then, 22 parts of diphenylmethane diisocyanate preheated to 25°C are added and stirred at 2000 rpm for 15 seconds to obtain a mixture. The mixture is injected into an open mold and foamed at a foaming temperature of 25°C and then cured at room temperature for 16 hours to finally obtain the sound-absorbing layer.

[0021] Preferably, the preparation method of epoxy-modified silica is as follows: 3-epoxypropoxypropyltrimethoxysilane is placed in anhydrous ethanol and stirred for 20 min to obtain a silane ethanol solution. The dried nano-silica is added to the silane ethanol solution and stirred and ultrasonically dispersed for 30 min. After centrifugation, the precipitate is washed and centrifuged multiple times, and then dried to obtain epoxy-modified silica.

[0022] Preferably, the preparation method of modified castor oil-based polyol is as follows: 100 parts of castor oil-based polyol, 30 parts of pentaerythritol, 1 part of p-toluenesulfonic acid, and 10 parts of toluene are mixed and stirred at 200°C for 4 hours to obtain a mixture. Then, 20 parts of stearic acid, 1 part of p-toluenesulfonic acid, and 10 parts of toluene are added to the mixture. The mixture is stirred at 160°C for 4 hours. After the reaction is completed, the mixture is cooled to room temperature, neutralized, washed with water multiple times, separated, evaporated, and dried to finally obtain the modified castor oil-based polyol.

[0023] Preferably, the preparation method of the sound insulation layer is as follows: 40-50 parts of gypsum powder, 4-6 parts of cement, 16-20 parts of blast furnace slag powder, 6-10 parts of fly ash, 30-35 parts of barite powder, and 4-8 parts of modified glass fiber are added to a mixer in sequence and dry-mixed for 5 minutes to obtain a dry mixture; 1 part of polycarboxylate superplasticizer and 0.5 parts of retarder are dissolved in deionized water to prepare a mixed solution; then, fumed silica dispersion and the mixed solution are added to the dry mixture in sequence, and 1 part of silicone oil emulsion waterproofing agent is added at the same time, and stirred for 8 minutes to prepare a gypsum-based slurry; the gypsum-based slurry is injected into a mold, allowed to stand, demolded, oxidized, and naturally dried to obtain the sound insulation layer.

[0024] Preferably, the modified glass fiber preparation method is as follows: chopped glass fibers are immersed in an aqueous sodium hydroxide solution, left to stand at room temperature for 1 hour, intermittently shaken, and finally washed and dried to obtain pretreated glass fibers; the pretreated glass fibers are immersed in a γ-methacryloyloxypropyltrimethoxysilane solution, stirred and reacted at room temperature for 2 hours, and the reaction product A is washed and dried for 12 hours to obtain silanized modified glass fibers; the silanized modified glass fibers are immersed in an initiator acetone solution, soaked at room temperature in the dark for 4 hours to obtain a modified glass fiber intermediate; under nitrogen protection, the modified glass fiber intermediate, methyl methacrylate monomer, hydroquinone, and toluene are stirred and reacted at 70°C for 6 hours to obtain reaction product B; reaction product B is Soxhlet extracted for 24 hours, then washed and dried to obtain modified glass fibers.

[0025] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0026] 1. In this invention, modified castor oil-based polyols construct the basic porous elastic framework required for the sound-absorbing layer, while epoxy-modified silica acts as a structure regulator to optimize the cell structure. For example, it may refine the cell size and increase the tortuosity of the pores, resulting in a longer propagation path for sound waves within the cells, increased reflection and scattering frequency, and more efficient energy dissipation. This, in turn, improves the sound absorption coefficient over a wider frequency range, achieving superior sound absorption performance. Epoxy-functionalized silica not only helps optimize the cell structure but also, as a nano-reinforcing filler, is uniformly dispersed within the cell wall framework of the polyurethane foam. Through chemical crosslinking of epoxy groups and polyol groups, silica particles form a strong interfacial bond with the polyurethane matrix, significantly enhancing the stiffness and strength of the cell wall framework, improving the load-bearing capacity and bending resistance of the sound-absorbing layer, and thus greatly improving static bending strength.

[0027] 2. In this invention, during the preparation of the sound insulation layer, gypsum provides early strength, cement provides mid- and late-stage strength, and blast furnace slag powder and fly ash contribute to late-stage strength through pozzolanic reaction, achieving synergistic development of early, mid-, and late-stage strength and constructing a matrix with continuously increasing strength. The pozzolanic reaction of blast furnace slag powder and fly ash consumes calcium hydroxide, a byproduct of cement hydration, generating more CSH gel, increasing the gel phase content, reducing harmful phases, and optimizing the composition of hydration products. Simultaneously, it can fill the pores between cement and gypsum hydration products, refining the pore structure, reducing porosity, and increasing the density of the matrix, thereby improving strength and durability. The overall strength and density of the matrix are enhanced, and the overall density of the material also improves the sound insulation performance of the sound insulation layer.

[0028] 3. In this invention, fumed silica is added to the sound insulation layer. On one hand, fumed silica, together with blast furnace slag powder and fly ash, participates in the pozzolanic reaction, more thoroughly consuming calcium hydroxide and generating more CSH gel, thus more effectively optimizing the composition and microstructure of hydration products. On the other hand, fumed silica fills pores at the nanoscale, improving the microstructure, while active mineral admixtures optimize the hydration reaction at the micrometer scale. Both work synergistically to enhance matrix properties at different scales, achieving deeper microstructure optimization, improving material density, and consequently enhancing sound insulation performance. Fumed silica not only strengthens the interface between hydration products but also strengthens the interface between active mineral admixtures and the cement gypsum matrix, forming a more uniform, continuous, and integrated composite matrix, synergistically improving the overall mechanical and durability properties of the matrix.

[0029] 4. In this invention, modified glass fiber is used in the sound insulation layer. Firstly, silanization modification introduces silane groups onto the glass fiber surface, which covalently bond with the silanol groups in the gypsum hydration products, forming -Si-O-Si- bonds, thus enhancing the interfacial adhesion between the fiber and the gypsum matrix. Grafting methyl methacrylate introduces organic segments, improving the wettability of the fiber surface, enabling the modified glass fiber to form a strong interfacial bond with the gypsum matrix and to be more evenly dispersed within the matrix. Hydrated gypsum matrix itself has high compressive strength but low tensile and flexural strength, making it a brittle material prone to cracking. Modified glass fiber acts as a "reinforcing skeleton" in the sound insulation layer. When the sound insulation layer is subjected to bending stress, the glass fiber, with its high tensile strength, effectively bears the tensile stress, limiting the initiation and propagation of cracks, significantly improving the static bending strength of the sound insulation layer. The strong interfacial bond between the glass fiber and the gypsum matrix ensures that stress can be effectively transferred from the matrix to the fiber, fully utilizing the reinforcing effect of the fiber. Meanwhile, modified glass fiber enhances the integrity and crack resistance of the sound insulation layer structure, reduces the generation and propagation of microcracks, and reduces the intrusion of water vapor and corrosive media, thereby synergistically improving the aging resistance of the sound insulation layer.

[0030] 5. In this invention, the flexible modified epoxy resin emulsion and the active amine curing agent work synergistically to construct a high-performance waterborne epoxy adhesive matrix. The flexible segments impart toughness to the adhesive layer, while the highly active amine curing agent ensures the curing speed and crosslinking density. The two balance the strength and toughness of the adhesive layer, enabling it to provide high bonding strength while adapting to the deformation of each layer of the decorative panel, thereby synergistically improving the static bending strength and aging resistance of the decorative panel. Simultaneously, the strong bond also reduces the penetration of water molecules, ensuring the overall water resistance of the decorative panel. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the multi-layer structure of the sound-insulating decorative panel of the present invention.

[0032] In the diagram: 1. Decorative layer; 2. Sound-absorbing layer; 3. Sound-insulating layer; 4. Back panel layer. Detailed Implementation

[0033] 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. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0034] Please see Figure 1 This invention provides a novel sound-insulating decorative panel and its preparation method, the technical solution of which is as follows:

[0035] Figure 1 The middle part is the novel sound-insulating decorative panel prepared in this invention. The novel sound-insulating decorative panel consists of the following layers from top to bottom: decorative layer 1, sound-absorbing layer 2, sound-insulating layer 3, and back panel layer 4.

[0036] The manufacturing process of the new soundproof decorative panel is as follows: First, double-modified epoxy adhesive is coated on the surface of the backing layer 4. The wet weight of the adhesive is controlled at 120-150 grams per square meter. The soundproof layer 3 is placed on the backing layer 4 coated with adhesive and pressed lightly to adhere. Then, the sound-absorbing layer 2 and the decorative layer 1 are assembled in sequence with the same coating amount to obtain the assembled multi-layer panel. The assembled multi-layer panel is hot-pressed and laminated. Finally, the pressed product is trimmed with an edge trimming machine and naturally cured for 72 hours to obtain the new soundproof decorative panel.

[0037] The raw materials used in this invention are sourced from the following sources:

[0038] Raw materials for dual-modified epoxy adhesives: waterborne epoxy resin emulsion (Olin, DER-WB3002 WB6001), waterborne amine curing agent (Hanssen EPikure Curing Agent 8535-W-50), dispersant (BYK-190 dispersant), defoamer (TEGO Foamex 810), and mildew inhibitor (Kason CAS No. 26172-55-4).

[0039] Sound-absorbing layer material: silicone oil foam stabilizer (Dow Corning DC-193);

[0040] Sound insulation layer raw materials: chopped glass fiber (Shandong Tonghui Glass Fiber Co., Ltd., 6mm), fumed nano silica (Cabot CAB-O-SIL TS620), polycarboxylate superplasticizer (Shanghai Hengchuang Chemical Co., Ltd. PC-1022), silicone oil emulsion waterproofing agent (Shandong Huling New Materials Co., Ltd., JC-330), citric acid retarder (CAS No. 77-92-9).

[0041] Example 1

[0042] (I) Preparation of the decorative layer

[0043] First, the materials are mixed according to the formula: 60 parts wood flour, 30 parts polyvinyl chloride resin, 3 parts composite lead hot salt stabilizer, 1 part stearic acid, and 1 part KH-550 are added sequentially to a high-speed mixer. The high-speed mixer is started, and the speed is set to 1000 rpm. Hot mixing is performed at 130°C for 10 minutes to ensure thorough and uniform mixing of all components and melting and plasticizing of the polyvinyl chloride resin, resulting in a homogeneous wood-plastic composite hot mix. Then, the wood-plastic hot mix is ​​immediately added to a mold preheated to 170°C. After mold closing, a pressure of 10 MPa is applied on a hydraulic press for compression molding. The molding time is set to 4 minutes based on the panel thickness. After molding, the mold is rapidly cooled to 45°C, and the decorative layer is removed from the mold.

[0044] (II) Preparation of the sound-absorbing layer

[0045] 2.1 Preparation of epoxy-modified silica

[0046] Ten parts of nano-silica powder were weighed and dried at 120℃ for 6 hours. Five parts of 3-epoxypropoxypropyltrimethoxysilane were added to 100 parts of anhydrous ethanol and stirred for 20 minutes. The pre-dried 10 parts of silica nano-powder were slowly and gradually added to a round-bottom flask containing a silane coupling agent ethanol solution. A stir bar was added, and the mixture was stirred and ultrasonically dispersed for 30 minutes. The reaction suspension was then transferred to a centrifuge tube and centrifuged at 4000 rpm for 5 minutes, leaving a precipitate. 50 parts of anhydrous ethanol were added to the centrifuge tube, and the mixture was stirred with a glass rod or ultrasonically dispersed. The centrifugation operation was repeated. This washing with anhydrous ethanol was repeated three times until the washing liquid was basically colorless. The washing operation was then repeated three times with deionized water, and the supernatant was poured off as much as possible. The washed product was dried at 60℃ for 12 hours to obtain epoxy-modified silica.

[0047] 2.2 Preparation of modified castor oil-based polyols

[0048] 100 parts of castor oil-based polyol were mixed with 30 parts of pentaerythritol and 1 part of p-toluenesulfonic acid as an esterification catalyst, and 10 parts of toluene as a solvent. The reaction was carried out under continuous nitrogen protection and stirred at 200°C for 4 hours to obtain a mixture. Then, 20 parts of stearic acid were added as a hydrophobic modifier, 1 part of p-toluenesulfonic acid as an esterification catalyst, and 10 parts of toluene as a solvent. The mixture was again purged with nitrogen and heated using an oil bath or heating mantle with a temperature control accuracy of ±2°C at 160°C for 4 hours. The generated water was recovered using a condenser equipped with a water separator. After the reaction is complete, cool to room temperature, add sodium carbonate or sodium hydroxide aqueous solution to neutralize the catalyst, separate the aqueous phase, wash with water several times until the aqueous phase is neutral, dry overnight with anhydrous sodium sulfate or anhydrous magnesium sulfate, filter to remove the desiccant, or use a rotary evaporator for vacuum distillation to remove the solvent and residual water, and then filter with filter paper or a sintered glass funnel to obtain the modified castor oil-based polyol. The hydroxyl value of the obtained modified castor oil-based polyol is 80 mg KOH / g.

[0049] 2.3 Preparation of sound-absorbing layer

[0050] First, 5 parts of epoxy-modified silica powder were added to 100 parts of modified castor oil-based polyol and dispersed at high speed for 30 minutes using a high-speed disperser or ultrasonic disperser to obtain a dispersion slurry. Then, 3 parts of deionized water, 1 part of triethylenediamine catalyst, 1 part of silicone oil foam stabilizer DC193, and 2 parts of epoxidized soybean oil were added to the dispersion slurry and mixed for 3 minutes to obtain a mixed system. Simultaneously, 22 parts of diphenylmethane diisocyanate with an NCO content of 31% were preheated to 25°C and quickly added to the mixed system, and stirred at 2000 rpm for 15 seconds using a high-speed stirrer. The mixture was then quickly poured into an open mold and foamed at 25°C. After foaming, it was cured at room temperature for 16 hours to finally obtain the sound-absorbing layer.

[0051] (III) Preparation of the sound insulation layer

[0052] 3.1 Preparation of Nano-Silica Dispersion by Gas Phase Method

[0053] Five parts of fumed nano-silica were slowly added to 30 parts of deionized water and ultrasonically stirred for 30 minutes. After dispersion, the mixture was allowed to stand for 24 hours to obtain a fumed nano-silica dispersion.

[0054] 3.2 Preparation of Modified Glass Fiber

[0055] Dissolve 1 part of solid sodium hydroxide in 100 parts of deionized water to prepare a 1.0% sodium hydroxide solution; mix 200 parts of anhydrous ethanol and 100 parts of deionized water to obtain a mixture, add 2 parts of γ-methacryloxypropyltrimethoxysilane to the mixture, stir for 30 min to prepare a γ-methacryloxypropyltrimethoxysilane solution; dissolve 1 part of benzoyl peroxide in 200 parts of acetone to prepare an initiator acetone solution, and store it in the dark; weigh 100 parts of chopped glass fiber, immerse it in the sodium hydroxide aqueous solution, let it stand and soak for 1 h at room temperature, shake intermittently, and finally wash and dry to obtain pretreated glass fiber.

[0056] Pretreated glass fibers were immersed in a γ-methacryloxypropyltrimethoxysilane solution and stirred at room temperature for 2 hours to obtain reaction product A. Reaction product A was washed three times with anhydrous ethanol to remove unreacted silane coupling agent, then washed once with acetone, and finally dried in a vacuum oven at 80°C for 12 hours to obtain silanized modified glass fibers. The silanized modified glass fibers were then immersed in an initiator acetone solution and soaked at room temperature in the dark for 4 hours to allow for complete adsorption of the initiator, resulting in a modified glass fiber intermediate. Under nitrogen protection, 100 parts of the modified glass fiber intermediate, 20 parts of methyl methacrylate monomer, 0.2 parts of hydroquinone, and 200 parts of toluene solvent were added to a three-necked flask equipped with a stirrer, thermometer, and condenser. The mixture was heated to 70°C and stirred at a constant temperature for 6 hours to carry out free radical graft polymerization, forming a polymethyl methacrylate graft layer, yielding reaction product B. After the reaction was completed, reaction product B was extracted with toluene using a Soxhlet extractor for 24 hours to remove ungrafted homopolymer. It was then washed three times each with acetone and anhydrous ethanol to remove residual solvent and monomer. Finally, it was dried in a vacuum oven at 60°C for 24 hours to obtain modified glass fibers.

[0057] 3.3 Preparation of the sound insulation layer

[0058] 40 parts gypsum powder, 4 parts cement, 16 parts blast furnace slag powder, 6 parts fly ash, 30 parts barite powder, and 6 parts modified glass fiber were sequentially added to a forced mixer and dry-mixed for 5 minutes. Then, 1 part polycarboxylate superplasticizer and 0.5 parts retarder were dissolved in deionized water to prepare a mixed solution. Next, the fumed silica dispersion and the mixed solution were sequentially added to the dry mix while stirring. Simultaneously, silane-based waterproofing agent or silicone oil emulsion waterproofing agent was slowly added, controlling the total water-cement ratio to 0.30. The mixture was stirred for 8 minutes to prepare a gypsum-based slurry. The gypsum-based slurry was quickly poured into a mold, and a vibrating table was used to assist the grouting process at a vibration frequency of 30 Hz for 1-2 minutes to remove air bubbles and improve density. After grouting, the mixture was allowed to stand for 30 minutes. After initial setting and demolding, the gypsum sound insulation layer was placed in a 50℃ constant temperature curing room for wet curing for 72 hours. After completion, it was naturally dried under ventilated conditions for 7 days to obtain the sound insulation layer.

[0059] (iv) Preparation of double-modified epoxy adhesives

[0060] The aqueous epoxy resin emulsion was preheated at 60°C for 30 minutes. Polytetrahydrofuran ether diol was vacuum dehydrated at 80°C for 1 hour and then added to the aqueous epoxy resin emulsion. The reaction was carried out at 70°C for 2 hours. After the reaction was completed, the mixture was cooled to about 50°C, and the emulsifier fatty alcohol polyoxyethylene ether was added. The mixture was stirred for another 30 minutes to obtain the modified epoxy resin.

[0061] Pour the water-based amine curing agent into a clean reaction vessel. While stirring, slowly add triethylenetetramine reactive diluent dropwise over 10 minutes. After the addition is complete, continue stirring for 20 minutes. Then, add 1 part of salicylic acid and 1 part of dispersant alkylphenol polyoxyethylene ether phosphate in sequence, and continue stirring for 30 minutes to obtain the reactive amine curing agent.

[0062] 100 parts of modified epoxy resin were added to a reactor and stirred at 150 rpm. 3 parts of nano-silica were dispersed in 20 parts of deionized water under ultrasonic stirring to prepare a nano-silica dispersion. The nano-silica dispersion was added to the modified epoxy resin and stirred for 20 min. Then, 3 parts of reactive diluent ethylene glycol butyl ether, 1 part of KH-560, 0.3 parts of waterborne polyurethane thickener, 0.2 parts of wetting and dispersing agent, 0.1 parts of defoamer, and 0.1 parts of mildew inhibitor were added to the reactor in sequence. After each component was added, stirring was continued for 10 min to obtain a mixed system. 40 parts of reactive amine curing agent were added to the mixed system and stirring was continued for 30 min. Then, the mixture was allowed to stand for 20 min to defoam, resulting in a double-modified epoxy adhesive.

[0063] (V) Preparation of new sound-insulating decorative panels

[0064] The back panel layer uses commercially available 5mm multi-layer plywood, and a double-modified epoxy adhesive is coated on the surface of the back panel layer, with the wet weight coating amount of the adhesive controlled at 150g / m². 2 The sound insulation layer is placed on the backing layer coated with adhesive and pressed lightly to adhere it. Then, the sound absorption layer and the decorative layer are assembled in sequence with the same coating amount to obtain an assembled multi-layer panel. The assembled panel is then hot-pressed at a temperature of 50°C, a pressure of 0.5MPa, and a time of 2 hours. After the pressed product is trimmed with an edge trimmer, it is naturally cured in a ventilated and shady place for 72 hours to obtain a new type of sound insulation decorative panel.

[0065] The difference between Example 2 and Example 1 lies in the amount of components used in preparing the sound-absorbing layer and the sound-insulating layer:

[0066] The raw materials for preparing the sound-absorbing layer include: 100 parts of modified castor oil-based polyol, 1 part of triethylenediamine catalyst, 2 parts of silicone oil foam stabilizer, and 7 parts of epoxy-modified silica.

[0067] The raw materials for preparing the sound insulation layer include: 45 parts gypsum powder, 5 parts cement, 18 parts blast furnace slag powder, 8 parts fly ash, 33 parts barite powder, 2 parts fumed nano silica, 1.0 part polycarboxylate superplasticizer, 0.3 parts citric acid retarder, 8 parts modified glass fiber, and 1 part silane waterproofing agent. The remaining parameters and conditions are the same.

[0068] The difference between Example 3 and Example 1 lies in the amount of components used in preparing the sound-absorbing layer and the sound-insulating layer:

[0069] The raw materials for preparing the sound-absorbing layer include: 100 parts of modified castor oil-based polyol, 1 part of triethylenediamine catalyst, 2 parts of silicone oil foam stabilizer, and 9 parts of epoxy-modified silica.

[0070] The raw materials for preparing the sound insulation layer include: 50 parts gypsum powder, 6 parts cement, 20 parts blast furnace slag powder, 10 parts fly ash, 35 parts barite powder, 5 parts fumed nano silica, 1.0 part polycarboxylate superplasticizer, 0.1 part citric acid retarder, 10 parts modified glass fiber, and 1 part silicone oil emulsion waterproofing agent. The remaining parameters and conditions are the same.

[0071] The difference between Example 4 and Example 1 lies in the amount of components used in preparing the sound-absorbing layer and the sound-insulating layer:

[0072] The raw materials for preparing the sound-absorbing layer include: 100 parts of modified castor oil-based polyol, 1 part of triethylenediamine catalyst, 2 parts of silicone oil foam stabilizer, and 7 parts of epoxy-modified silica.

[0073] The raw materials for preparing the sound insulation layer include: 50 parts gypsum powder, 6 parts cement, 20 parts blast furnace slag powder, 10 parts fly ash, 35 parts barite powder, 5 parts fumed nano silica, 1.0 part polycarboxylate superplasticizer, 0.1 part citric acid retarder, 10 parts modified glass fiber, and 1 part silicone oil emulsion waterproofing agent. The remaining parameters and conditions are the same.

[0074] The difference between Example 5 and Example 1 lies in the amount of components used in preparing the sound-absorbing layer and the sound-insulating layer:

[0075] The raw materials for preparing the sound-absorbing layer include: 100 parts of modified castor oil-based polyol, 1 part of triethylenediamine catalyst, 2 parts of silicone oil foam stabilizer, and 9 parts of epoxy-modified silica.

[0076] The raw materials for preparing the sound insulation layer include: 45 parts gypsum powder, 5 parts cement, 18 parts blast furnace slag powder, 8 parts fly ash, 33 parts barite powder, 2 parts fumed nano silica, 1.0 part polycarboxylate superplasticizer, 0.3 parts citric acid retarder, 8 parts modified glass fiber, and 1 part silane waterproofing agent. The remaining parameters and conditions are the same.

[0077] The difference between Comparative Example 1 and Example 1 is that the castor oil-based polyol in the raw materials for preparing the sound-absorbing layer is not modified, while the other parameters and conditions are the same.

[0078] The difference between Comparative Example 2 and Example 1 is that the silica used in the preparation of the sound-absorbing layer is not epoxy modified, while the other parameters and conditions are the same.

[0079] The difference between Comparative Example 3 and Example 1 is that the foaming temperature in the preparation of the sound-absorbing layer is 70°C, while the other parameters and conditions are the same.

[0080] The difference between Comparative Example 4 and Example 1 is that the curing time in the preparation of the sound-absorbing layer is 8 hours, while the other parameters and conditions are the same.

[0081] The difference between Comparative Example 5 and Example 1 is that no blast furnace slag powder was added during the preparation of the sound insulation layer, while the other parameters and conditions were the same.

[0082] The difference between Comparative Example 6 and Example 1 is that no fly ash was added during the preparation of the sound insulation layer, while the other parameters and conditions were the same.

[0083] The difference between Comparative Example 7 and Example 1 is that silicate cement was used in the preparation of the sound insulation layer, while the other parameters and conditions were the same.

[0084] The difference between Comparative Example 8 and Example 1 is that the particle size of the blast furnace slag powder was 200 mesh during the preparation of the sound insulation layer, while the other parameters and conditions were the same.

[0085] The difference between Comparative Example 9 and Example 1 is that no modified glass fiber was added during the preparation of the sound insulation layer, while the other parameters and conditions were the same.

[0086] The difference between Comparative Example 10 and Example 1 is that, in the preparation of the sound insulation layer, unmodified chopped glass fibers were used instead of modified glass fibers, while the other parameters and conditions were the same.

[0087] The difference between Comparative Example 11 and Example 1 is that, in the preparation process of the sound insulation layer, the modified glass fiber intermediate is used instead of the modified glass fiber, while the other parameters and conditions are the same.

[0088] The difference between Comparative Example 12 and Example 1 is that no fumed silica nanoparticles are added during the preparation of the sound insulation layer.

[0089] Test Example 1

[0090] Test subjects: The novel sound-insulating decorative panels finally prepared in Examples 1-5 and Comparative Examples 1-11 were used for testing.

[0091] Test methods: (1) Sound insulation (frequency range: 2000-5000Hz) and sound absorption coefficient (1600-2000Hz) are tested in accordance with GB / T19889.3-2005 Acoustics of buildings and building components - Part 3: Laboratory measurement of airborne sound insulation of building components;

[0092] (2) The static bending strength and water absorption swelling degree test shall be conducted in accordance with GB / T17657-2022 Test Methods for Physical and Chemical Properties of Wood-based Panels and Decorative Wood-based Panels;

[0093] (3) The test method for aging resistance is: ((static bending strength before aging - static bending strength after aging) / static bending strength before aging) * 100%. The smaller the result, the stronger the aging resistance.

[0094] The final test results are shown in Table 1.

[0095] Table 1. Test results of sound insulation and sound absorption coefficient for Examples 1-5 and Comparative Examples 1-12

[0096]

[0097] In Comparative Example 1, unmodified castor oil-based polyols were used, reducing the number of cross-linking hydroxyl groups, which lowered the cross-linking density of the polyurethane sound-absorbing layer, making the three-dimensional network structure sparser and weakening intermolecular forces. Microscopically, the cell walls became thinner, larger, and more porous, resulting in a looser structure. This led to reduced sound wave energy dissipation efficiency, decreased sound insulation, weakened resistance to external forces, and reduced static bending strength. Although high-frequency sound absorption performance may improve, the overall sound absorption coefficient did not change significantly. The increased porosity led to increased water absorption and swelling, and poorer aging resistance.

[0098] In Comparative Example 2, the unmodified silica has fewer surface-active groups, making it unable to form strong covalent bonds with the polyurethane matrix. The interfacial bonding relies mainly on physical interactions, resulting in weakened bonding strength. Microscopically, it exhibits poor dispersibility, is prone to aggregation, and has microcracks and voids at the interface, reducing stress transfer efficiency and weakening the reinforcing effect. Macroscopically, it shows reduced static bending strength, slightly decreased sound insulation and sound absorption coefficients, decreased resistance to water molecule penetration, slightly increased water absorption and swelling, and poorer aging resistance.

[0099] In Comparative Example 3, the foaming temperature of the sound-absorbing layer was increased to 70℃, accelerating foaming and curing. This shortened the diffusion and mixing time of the components, making cell nucleation and growth difficult to control. The foam stabilizer was insufficient, leading to easy foam collapse and uneven cell structure. Microscopically, uneven cell size distribution, partial collapse, or increased closed-cell ratio resulted in a reduction in open-cell interconnection structures, hindering sound wave dissipation and significantly decreasing sound insulation and absorption coefficient. Other performance aspects were less affected. Meanwhile, Comparative Example 4 shows that when the curing time of the sound-absorbing layer was shortened to 8 hours, the cross-linking reaction was insufficient, the polyurethane network was not fully established, unreacted groups were present, molecular chain movement was restricted, and there were many network structural defects. Microscopically, the network structure was incomplete, the cross-linking density was insufficient, and micropores and defects were present, affecting mechanical and acoustic performance. Macroscopically, the static bending strength decreased, the sound insulation and absorption coefficient slightly decreased, the resistance to water molecules decreased, the water absorption expansion increased, and the aging resistance decreased.

[0100] In Comparative Example 5, the sound insulation layer lacks blast furnace slag powder, thus lacking the pozzolanic effect and failing to generate additional hydrated calcium silicate gel. This results in a reduction of the cement stone gel phase and an increase in unhydrated particles and pores. Microscopically, the cement stone structure is loose, with increased porosity and decreased density, weakening sound wave energy attenuation and reducing sound insulation. The reduction in CSH gel lowers strength, significantly decreasing static bending strength. The loose structure leads to increased water absorption and swelling, reducing aging resistance. In Comparative Example 6, the sound insulation layer lacks fly ash, resulting in a less severe loss of the pozzolanic effect due to the continued activity provided by blast furnace slag powder. Microscopically, the cement stone density slightly decreases and porosity slightly increases, with less overall structural change than in Comparative Example 5. Macroscopically, sound insulation and static bending strength slightly decrease, and other properties are also slightly affected, indicating that fly ash plays a supporting optimization role. Similarly, Comparative Example 7 shows that replacing low-alkalinity sulfoaluminate cement with ordinary silicate cement in the sound insulation layer alters the hydration products, potentially changing the crystal morphology, packing method, and pore structure microscopically, but with a limited decrease in density. Performance is minimally affected.

[0101] As can be seen from Comparative Example 8, when the particle size of blast furnace slag powder increases to 200 mesh, the specific surface area decreases, the pozzolanic reactivity is inhibited, the degree of reaction with cement hydration decreases, and the pozzolanic effect weakens. Microscopically, the number of unreacted slag powder particles increases, CSH gel decreases, cement stone density decreases, porosity increases, and pore size distribution widens. Macroscopically, sound insulation and static bending strength decrease, resistance to water molecule penetration decreases, water absorption expansion increases, and aging resistance deteriorates.

[0102] In Comparative Example 9, the sound insulation layer did not contain modified glass fiber. The cement-based material lacked fiber reinforcement, resulting in reduced tensile strength and fracture toughness, and weakened resistance to external forces. Microscopically, the lack of fiber bridging made cracks prone to initiation and propagation, increasing microcracks and reducing structural integrity. Macroscopically, static bending strength decreased, aging resistance reduced, water absorption increased, and water absorption expansion increased, while sound insulation and sound absorption coefficients were only slightly affected.

[0103] In Comparative Example 10, the sound insulation layer used unmodified chopped glass fibers instead of modified glass fibers. The fiber surface was not effectively modified, and the interfacial bonding relied on physical processes, resulting in weakened bonding strength and reduced stress transfer efficiency. Microscopically, the interface contained pores and microcracks, and the interfacial transition zone was loose, making it difficult for the fiber reinforcement to function effectively. Macroscopically, the static bending strength was lower than in Example 1 but higher than in Comparative Example 9. Water absorption swelling and aging resistance were lower than in Example 1 but better than in Comparative Example 9. The sound insulation and sound absorption coefficients were similar to those of Example 1.

[0104] In Comparative Example 11, the sound insulation layer used a modified glass fiber intermediate instead of the final modified glass fiber. The intermediate was only modified with a silane coupling agent and did not undergo methyl methacrylate graft copolymerization, resulting in a low degree of modification. Microscopically, the interfacial bonding strength was lower than that of Example 1 but slightly better than that of Comparative Example 10, with fiber reinforcement and durability improvement effects falling between the two. Macroscopically, the static bending strength, water absorption swelling, and aging resistance were between those of Example 1 and Comparative Example 10, while the sound insulation and sound absorption coefficient were basically the same as those of Example 1, indicating that methyl methacrylate graft copolymerization modification is very important.

[0105] In Comparative Example 12, the absence of fumed silica in the preparation of the sound insulation layer resulted in the lack of nanoscale active fillers within the gypsum-based slurry. Consequently, the calcium hydroxide, a cement hydration product, lacked efficient secondary pozzolanic reaction, leading to a reduction in the amount of CSH gel generated and a looser microstructure in the sound insulation layer matrix material. Simultaneously, the absence of nano-silica also caused the disappearance of the nanopore filling effect within the slurry, resulting in increased porosity, deteriorated pore size distribution, reduced material density, and increased microstructural defects. This microstructural degradation leads to a decline in both the acoustic and mechanical properties of the sound insulation layer.

[0106] The difference between Example 6 and Example 4 is that the amount of each component used in the preparation of the double-modified epoxy adhesive is different: 5 parts of reactive diluent ethylene glycol butyl ether, 1.5 parts of KH-560, 0.5 parts of waterborne polyurethane thickener, 0.3 parts of wetting and dispersing agent, 0.15 parts of defoamer, 0.15 parts of mildew inhibitor, and 45 parts of reactive amine curing agent.

[0107] The difference between Example 7 and Example 4 is that the amount of each component used in the preparation of the double-modified epoxy adhesive is different: 7 parts of reactive diluent ethylene glycol butyl ether, 2 parts of KH-560, 0.7 parts of waterborne polyurethane thickener, 0.4 parts of wetting and dispersing agent, 0.2 parts of defoamer, 0.2 parts of mildew inhibitor, and 50 parts of reactive amine curing agent.

[0108] The difference between Examples 8-12 and Example 6 lies in the final amount of adhesive applied and the parameters during the pressing of the decorative panel, as shown in Table 2.

[0109] Table 2 Parameter Table for Examples 6 and 8-12

[0110]

[0111] The difference between Comparative Example 13 and Example 6 is that the waterborne epoxy resin emulsion was not modified during the preparation of the dual-modified epoxy adhesive, while the other parameters and conditions were the same.

[0112] The difference between Comparative Example 14 and Example 6 is that the water-based amine curing agent is not modified during the preparation of the double-modified epoxy adhesive, while the other parameters and conditions are the same.

[0113] The difference between Comparative Example 15 and Example 6 is that, in the preparation of the dual-modified epoxy adhesive, the nano silica dispersion, the reactive diluent ethylene glycol butyl ether, KH-560, the waterborne polyurethane thickener, the wetting and dispersing agent, the defoamer and the mildew inhibitor were mixed together and then added to the reactor containing the modified epoxy resin. The other parameters and conditions were the same.

[0114] The difference between Comparative Example 16 and Example 6 is that, in the preparation process of the double-modified epoxy adhesive, the nano silica dispersion was added first, followed by the addition of silane coupling agent KH-560, reactive diluent ethylene glycol butyl ether, waterborne polyurethane thickener, wetting and dispersing agent, defoamer and mildew inhibitor in sequence, while the remaining parameters and conditions were the same.

[0115] The difference between Comparative Example 17 and Example 6 is that, in the preparation process of the double-modified epoxy adhesive, the nano silica dispersion was added first, followed by the addition of the reactive diluent ethylene glycol butyl ether, the waterborne polyurethane thickener, the wetting and dispersing agent, the silane coupling agent KH-560, the defoamer, and the mildew inhibitor. The remaining parameters and conditions were the same.

[0116] The difference between Comparative Example 18 and Example 6 is that the hot pressing temperature is 100°C, while the other parameters and conditions are the same.

[0117] Test Example 2

[0118] Test subjects: The decorative panels finally prepared in Examples 6-12 and Comparative Examples 13-18 were tested.

[0119] The test method is the same as that of Test Example 1, and the final test results are shown in Table 3.

[0120] Table 3. Test results of Examples 4, 6-12 and Comparative Examples 13-18

[0121]

[0122] Comparative Example 13 eliminated the modification of the waterborne epoxy resin emulsion with polytetrahydrofuran ether diol, resulting in the absence of flexible polyether segments in the epoxy resin molecular chain and a reduction in long-chain flexible ether bonds. This altered the microstructure of the cured double-modified epoxy adhesive, restricting molecular chain activity, increasing the rigidity and brittleness of the crosslinking network, reducing molecular chain flexibility and energy dissipation pathways, thus decreasing the sound insulation and sound absorption coefficients of the decorative panel. Simultaneously, the rigid structure facilitates stress concentration, reducing resistance to bending deformation and decreasing static bending strength; the internal free volume of the material increases, exposing more hydrophilic hydroxyl groups, increasing water absorption and swelling, and worsening aging resistance.

[0123] In Comparative Example 14, the waterborne amine curing agent was not modified with triethylenetetramine, resulting in a lack of flexible amine long chains in its molecular structure, which affects the curing reaction with epoxy resin and the construction of the crosslinking network. The unmodified curing agent has fewer crosslinking reaction sites, a sparse and incomplete crosslinking network, reduced crosslinking density, and a loose microstructure in the adhesive layer. This weakens the intermolecular forces, reducing the static bending strength and sound insulation of the decorative panel; the numerous defects in the crosslinking network lead to low sound wave energy dissipation efficiency, further decreasing sound insulation, and also weakening its resistance to corrosion, water absorption swelling, and aging resistance.

[0124] In Comparative Example 15, the sequential addition process was disrupted by adding the nano-silica dispersion and other components all at once, thus breaking the progressive reinforcement of the microenvironment. Nano-silica is difficult to disperse in high-viscosity matrices, easily agglomerating and losing its nano-advantages. Microscopically, agglomerates worsen structural uniformity, concentrate stress, hinder the diffusion and bonding of silane coupling agents, reduce interfacial bonding strength, and decrease stress transfer efficiency. Nano-silica agglomerates not only hinder silane coupling agent bonding but also impede the effective propagation and energy dissipation of sound waves within the material. Macroscopically, the mechanical properties of the double-modified epoxy adhesive decrease, the static bending strength, sound insulation, and sound absorption coefficient of the decorative panel decrease, water absorption increases, and aging resistance deteriorates.

[0125] In Comparative Example 16, adjusting the order of silane coupling agent addition, while ensuring initial dispersion of nano-silica, altered the microenvironment for interfacial modification. Adding the reactive diluent first may lead to competitive adsorption on the nano-silica surface, hindering the contact and bonding between the silane coupling agent and surface hydroxyl groups, thus reducing interfacial modification efficiency. Microscopically, the degree of interfacial chemical bonding decreases, affecting bond strength and density, and reducing stress transfer efficiency. Macroscopically, the interface and mechanical properties of the double-modified epoxy adhesive are slightly reduced, the static bending strength and sound insulation of the decorative panel decrease slightly, while the sound absorption coefficient and durability show no significant changes. Combining the order in Comparative Example 17, further delaying the addition of the silane coupling agent worsens its interfacial modification microenvironment. The waterborne polyurethane thickener increases the system viscosity, forming a polymeric entanglement network, while the wetting and dispersing agent forms an adsorption layer, hindering the diffusion of the silane coupling agent, reducing reaction sites, and significantly weakening the interfacial modification efficiency. Microscopically, the degree of interfacial chemical bonding, bond strength, and density decrease, defects increase, and stress transfer efficiency decreases. On a macroscopic level, the performance of the double-modified epoxy adhesive deteriorates, but the nano-silica is still somewhat dispersed, slowing down the rate of performance decline. The static bending strength and sound insulation of the decorative panel decrease slightly, while the sound absorption coefficient and durability are basically unaffected.

[0126] Comparative Example 18 raised the hot-pressing temperature to 100℃. The high temperature accelerated the curing reaction of the double-modified epoxy adhesive, making heat dissipation difficult. This resulted in thermal stress concentration within the decorative panel, weakening intermolecular forces and even causing bond breakage. Defects such as microcracks and voids appeared in the adhesive layer, reducing its density and strength. Simultaneously, the high temperature accelerated the thermal decomposition of the polyurethane foam in the sound-absorbing layer, damaging its pore structure. The wood flour and polyvinyl chloride resin in the decorative layer also faced the risk of thermal degradation. Macroscopically, the decorative panel's static bending strength, sound insulation, and sound absorption coefficient decreased, while its water absorption expansion and aging resistance were affected, leading to a decline in overall performance.

[0127] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A novel sound-insulating decorative panel, characterized in that: The novel sound-insulating decorative panel consists of four layers: a decorative layer, a sound-absorbing layer, a sound-insulating layer, and a backing layer; wherein, by weight, The raw materials for preparing the decorative layer include: wood flour, polyvinyl chloride resin, composite lead hot salt stabilizer, stearic acid, and KH-550. The raw materials for preparing the sound-absorbing layer include: 100 parts of modified castor oil-based polyol, 1 part of triethylenediamine, 2 parts of silicone oil foam stabilizer, 5-9 parts of epoxy-modified silica, 2 parts of epoxidized soybean oil, and diphenylmethane diisocyanate. The raw materials for preparing the sound insulation layer include: 40-50 parts gypsum powder, 4-6 parts cement, 16-20 parts blast furnace slag powder, 6-10 parts fly ash, 30-35 parts barite powder, 5 parts fumed nano silica, 1 part polycarboxylate superplasticizer, 0.5 parts citric acid retarder, 6-10 parts modified glass fiber, and 1 part silicone oil emulsion waterproofing agent. The back panel is a commercially available 5mm thick multi-layer plywood.

2. The novel sound-insulating decorative panel according to claim 1, characterized in that: The cement is a low-alkalinity sulfoaluminate cement; the blast furnace slag powder has a particle size of 400 mesh.

3. A method for preparing the novel sound-insulating decorative panel as described in any one of claims 1-2, characterized in that: The preparation method of the novel sound-insulating decorative panel is as follows: a double-modified epoxy adhesive is coated on the surface of the backing layer, and the wet weight coating amount is controlled at 120-150 g / m². 2 The sound insulation layer is placed on the backing layer coated with adhesive and pressed lightly to adhere it. Then, the sound absorption layer and the decorative layer are applied in sequence with the same amount of coating to obtain the assembled panel. The assembled panel is then hot-pressed at a temperature of 50-60℃, a pressure of 0.3-0.5MPa, and a hot-pressing time of 2 hours. After the pressed product is trimmed, it is cured for 72 hours to obtain the new sound insulation decorative panel.

4. The method for preparing the novel sound-insulating decorative panel according to claim 3, characterized in that: The preparation method of the dual-modified epoxy adhesive is as follows: 100 parts of modified epoxy resin are added to a reaction vessel and stirred at 150 rpm. First, nano-silica dispersion is added and stirring is continued for 20 min. Then, 3-7 parts of ethylene glycol butyl ether, 1-2 parts of KH-560, 0.3-0.7 parts of waterborne polyurethane, 0.2-0.4 parts of dispersant, 0.1-0.2 parts of defoamer, and 0.1-0.2 parts of mildew inhibitor are added to the reaction vessel in sequence. After each component is added, stirring is continued for 10 min to obtain a mixed system. 40-50 parts of active amine curing agent are added to the mixed system and stirring is continued for 30 min. Then, the mixture is allowed to stand for defoaming for 20 min to obtain the dual-modified epoxy adhesive.

5. The method for preparing the novel sound-insulating decorative panel according to claim 4, characterized in that: The aqueous epoxy resin emulsion was preheated at 60°C for 30 minutes. Polytetrahydrofuran ether diol was vacuum dehydrated at 80°C for 1 hour and then added to the aqueous epoxy resin emulsion. The mixture was reacted at 70°C for 2 hours. After the reaction was completed, the mixture was cooled to about 50°C, and fatty alcohol polyoxyethylene ether was added. The mixture was stirred for another 30 minutes to obtain the modified epoxy resin. Pour the water-based amine curing agent into a clean reaction vessel, and slowly add triethylenetetramine reactive diluent dropwise over 10 minutes while stirring. After the addition is complete, continue stirring for 20 minutes. Then, add salicylic acid and alkylphenol polyoxyethylene ether phosphate in sequence, and continue stirring for 30 minutes to obtain the reactive amine curing agent.

6. The method for preparing the novel sound-insulating decorative panel according to claim 3, characterized in that: The sound-absorbing layer is prepared as follows: 5-7 parts of epoxy-modified silica are added to 100 parts of modified castor oil-based polyol and dispersed at high speed for 30 minutes to obtain a dispersion slurry. Then, 2-3 parts of deionized water, 0.5-1 parts of triethylenediamine catalyst, 0.5-1 parts of silicone oil foam stabilizer, and 1-3 parts of epoxidized soybean oil are added to the dispersion slurry and mixed for 3 minutes. Then, 22 parts of diphenylmethane diisocyanate preheated to 25°C are added and stirred at 2000 rpm for 15 seconds to obtain a mixture. The mixture is injected into an open mold and foamed at a foaming temperature of 25°C, and then cured at room temperature for 16 hours to finally obtain the sound-absorbing layer.

7. The method for preparing the novel sound-insulating decorative panel according to claim 6, characterized in that: The preparation method of the epoxy-modified silica is as follows: 3-epoxypropoxypropyltrimethoxysilane is placed in anhydrous ethanol and stirred for 20 min to obtain a silane ethanol solution. The dried nano-silica is added to the silane ethanol solution and stirred and ultrasonically dispersed for 30 min. After centrifugation, the precipitate is washed and centrifuged multiple times, and then dried to obtain epoxy-modified silica. The modified castor oil-based polyol is prepared as follows: 100 parts of castor oil-based polyol, 30 parts of pentaerythritol, 1 part of p-toluenesulfonic acid, and 10 parts of toluene are mixed and stirred at 200°C for 4 hours to obtain a mixture. Then, 20 parts of stearic acid, 1 part of p-toluenesulfonic acid, and 10 parts of the toluene are added to the mixture. The mixture is stirred at 160°C for 4 hours. After the reaction is completed, the mixture is cooled to room temperature, neutralized, washed with water multiple times, separated, evaporated, and dried to finally obtain the modified castor oil-based polyol.

8. The method for preparing the novel sound-insulating decorative panel according to claim 3, characterized in that: The method for preparing the sound insulation layer is as follows: 40-50 parts of gypsum powder, 4-6 parts of cement, 16-20 parts of blast furnace slag powder, 6-10 parts of fly ash, 30-35 parts of barite powder and 4-8 parts of modified glass fiber are added to a mixer in sequence and dry-mixed for 5 minutes to obtain a dry mixture. One part of polycarboxylate superplasticizer and 0.5 parts of retarder are dissolved in deionized water to prepare a mixed solution; then, the fumed silica dispersion and the mixed solution are added to the dry mixture in sequence, and one part of silicone oil emulsion waterproofing agent is added at the same time. The mixture is stirred for 8 minutes to prepare a gypsum-based slurry; the gypsum-based slurry is injected into a mold, allowed to stand, demolded, oxidized and naturally dried to obtain the sound insulation layer.

9. The method for preparing the novel sound-insulating decorative panel according to claim 8, characterized in that: The modified glass fiber preparation method is as follows: Short-cut glass fibers are immersed in an aqueous sodium hydroxide solution and allowed to stand at room temperature for 1 hour, followed by intermittent shaking, and finally washed and dried to obtain pretreated glass fibers; the pretreated glass fibers are immersed in a γ-methacryloyloxypropyltrimethoxysilane solution and stirred at room temperature for 2 hours, and the reaction product A is washed and dried for 12 hours to obtain silanized modified glass fibers; the silanized modified glass fibers are immersed in an initiator acetone solution and soaked at room temperature in the dark for 4 hours to obtain a modified glass fiber intermediate; under nitrogen protection, the modified glass fiber intermediate, methyl methacrylate monomer, hydroquinone, and toluene are stirred at 70°C for 6 hours to obtain reaction product B, and the reaction product B is extracted by Soxhlet extraction for 24 hours, then washed and dried to obtain the modified glass fibers.

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