Flexible sound insulation prefabricated insulation board and production method thereof

Abstract

The invention discloses a flexible sound insulation prefabricated insulation board which comprises a prefabricated insulation layer, a steel bar truss embedded in the prefabricated insulation layer and a steel bar mesh bound to the bottom of the steel bar truss, a sound insulation surface layer is arranged on the side, facing a cast-in-place layer, of the prefabricated insulation layer, and the outer surface of the part, exposed out of the prefabricated insulation layer, of the steel bar truss is coated with a sound insulation isolation layer. The prefabricated heat preservation layer is a flexible light heat preservation concrete layer, and the flexible light heat preservation concrete layer is formed by mixing light heat preservation concrete with flexible powder. The prefabricated heat preservation layer is arranged to be a flexible light heat preservation concrete layer, and consumption of the prefabricated heat preservation layer to sound wave energy is improved; by arranging the sound insulation surface layer and the sound insulation isolation layer, a complete sound insulation interface is formed between the prefabricated heat preservation layer and the cast-in-place layer of the floor, continuous transmission of sound waves is effectively blocked, sound bridges are prevented, and the sound insulation performance of the flexible sound insulation prefabricated heat preservation plate and the sound insulation performance of the floor with the flexible sound insulation prefabricated heat preservation plate are greatly improved. The invention further discloses a production method of the flexible sound insulation prefabricated insulation board.

Description

Technical Field

[0001] The present invention relates to the technical field of prefabricated buildings, and particularly to a flexible sound-insulating prefabricated thermal insulation board and a production method thereof. Background Art

[0002] In existing prefabricated buildings, the floor slabs mainly adopt thermal insulation composite floor slabs, including prefabricated thermal insulation boards made of thermal insulation concrete materials and floor surface cast-in-place layers laminated on the prefabricated thermal insulation boards. The steel bar trusses embedded in the prefabricated thermal insulation boards form rigid connections with the floor surface cast-in-place layers. The vibration of the floor slab is easily transmitted to the prefabricated thermal insulation board or other structural parts of the floor slab through the steel bar trusses, thus forming a sound bridge. Usually, the prefabricated thermal insulation board is a porous elastic layer arranged under the floor slab and has a certain sound absorption effect, but has little effect on blocking impact sound..

[0003] At present, the sound insulation and noise reduction treatment methods of the existing thermal insulation composite floor slabs are mainly to laminate a cast-in-place layer on the prefabricated thermal insulation board as the structural layer, and then sequentially construct a sound insulation layer and a protective layer after the cast-in-place layer is formed, resulting in an increase in the structural thickness and a decrease in the storey height of the building; at the same time, the on-site construction operation procedures are increased, which not only makes the construction process more cumbersome, but also increases the difficulty and cost of construction management. Summary of the Invention

[0004] The present invention aims to provide a flexible sound-insulating prefabricated thermal insulation board, which can comprehensively improve the sound insulation performance of the floor system while ensuring the thermal insulation performance of the floor surface, and overcome the problems of complex construction, increased thickness, and sound bridge existing in the prefabricated thermal insulation board in the prior art.

[0005] To achieve the above object, the technical solution of the present invention is: to construct a flexible sound-insulating prefabricated thermal insulation board, including a prefabricated thermal insulation layer, a steel bar truss embedded in the prefabricated thermal insulation layer, and a steel bar mesh tied to the bottom of the steel bar truss. A sound insulation surface layer is provided on one side of the prefabricated thermal insulation layer facing the cast-in-place layer. A sound insulation isolation layer is provided on the outer surface of the part of the steel bar truss exposed from the prefabricated thermal insulation layer. The prefabricated thermal insulation layer is a flexible lightweight thermal insulation concrete layer, and the flexible lightweight thermal insulation concrete layer is made by mixing lightweight thermal insulation concrete with flexible powder.

[0006] Furthermore, the lightweight thermal insulation concrete is modified polystyrene particle concrete, and the flexible powder is graphite or rubber powder; the modified polystyrene particle concrete has good thermal insulation performance and lower bulk density.

[0007] Furthermore, a rubber cushion block is provided between the steel bar truss and the steel bar mesh; the rubber gasket can effectively cut off the sound bridge and reduce structure-borne sound, further improving the sound insulation performance of the prefabricated thermal insulation board.

[0008] Furthermore, a rubber cushion block is provided between the steel bar mesh and the side surface of the prefabricated thermal insulation layer away from the cast-in-place layer.

[0009] Furthermore, the sound insulation surface layer is a cement-based sound insulation coating layer, which can not only meet the sound insulation requirements, but also combine well with the precast thermal insulation layer and the cast-in-place concrete, ensuring the integrity of the floor structure.

[0010] Furthermore, a crack-resistant surface layer is provided on the side of the precast thermal insulation layer of the precast thermal insulation board away from the cast-in-place layer; further enhancing the tensile strength and crack resistance of the precast thermal insulation board and improving the stability of the overall structure of the precast thermal insulation board.

[0011] Another technical problem to be solved by the present invention is to provide a production method of a flexible sound insulation precast thermal insulation board to ensure that the above-mentioned flexible sound insulation precast thermal insulation board can be mass-produced.

[0012] The technical solution for the present invention to solve another technical problem is: constructing a production method of a flexible sound insulation precast thermal insulation board as described above, including the following steps: S10. Prepare lightweight thermal insulation concrete, mix in flexible powder and stir evenly to form flexible lightweight thermal insulation concrete; prepare the materials required for the sound insulation surface layer and the sound insulation isolation layer; S20. Cut the steel mesh according to the size of the flexible sound insulation precast thermal insulation board, and tie the steel truss to the steel mesh at the preset position; S30. Install the mold according to the size of the flexible sound insulation precast thermal insulation board, clean the template surface, and evenly spray the mold release agent; S40. Pour the flexible lightweight thermal insulation concrete prepared in step S10 into the mold according to the preset thickness and level it to form a flexible lightweight thermal insulation concrete layer; S50. Evenly scrape the sound insulation surface layer material prepared in step S10 on the surface of the flexible lightweight thermal insulation concrete layer formed in S30, and ensure that the thickness meets the preset requirements; S60. Press the combined steel truss and steel mesh in step S20 into the flexible lightweight thermal insulation concrete layer, and vibrate the bottom of the mold synchronously during pressing; S70. Spray the sound insulation isolation layer material prepared in step S10 on the steel truss to form a sound insulation isolation layer, and ensure that its thickness meets the preset requirements; S80. Cure and form.

[0013] Furthermore, in step S20, rubber cushion blocks are also tied between the steel truss and the steel mesh.

[0014] Furthermore, after step 30, the following steps are also included: S31. Evenly draw polymer cement with a preset thickness in the mold, and then fully lay the grid cloth to form a crack-resistant surface layer.

[0015] Implementing the flexible sound-insulating precast thermal insulation board of the present invention and its production method has the following beneficial effects: By providing a sound-insulating surface layer on the side of the precast thermal insulation layer facing the cast-in-place layer, this sound-insulating surface layer forms a sound-insulating interface between the precast thermal insulation board and the cast-in-place layer, which can effectively block the continuous transmission of sound waves, thereby effectively improving the sound-insulating performance of the entire floor slab; By covering the outer surface of the exposed steel bar truss with a sound-insulating isolation layer, a layer of sound-insulating material is provided between the steel bar truss and the cast-in-place concrete of the floor slab, completely blocking the formation of sound bridges by the steel bar truss in the thermal insulation floor slab, and further improving the sound-insulating performance of the entire floor slab. By setting the precast thermal insulation layer as a flexible lightweight thermal insulation concrete layer, which is made by mixing lightweight thermal insulation concrete with flexible powder, the flexible powder can improve the damping coefficient of the precast thermal insulation layer for sound conduction, enabling energy exchange of sound waves in the flexible powder, thereby consuming the transmission energy of sound waves and further improving the sound-insulating performance of the precast thermal insulation board. In addition, the sound-insulating interface and the sound-insulating isolation layer can be completed in the factory, with more stable overall quality, reduced on-site construction procedures, and a significant reduction in material usage. This flexible sound-insulating precast thermal insulation board improves the sound-insulating performance while ensuring the original thermal insulation performance, without increasing the thickness of the entire floor slab, and has a wider application range.

[0016] In its production method, first, flexible lightweight thermal insulation concrete is poured into the mold to form a flexible lightweight thermal insulation concrete layer, then a sound-insulating surface layer material is scraped on the surface, and then the combined steel bar truss and steel mesh are pressed into the flexible lightweight thermal insulation concrete layer. While pressing, the bottom of the mold is vibrated, greatly protecting the integrity of the sound-insulating surface layer; avoiding the problems in the prior art that it is inconvenient to scrape the sound-insulating surface layer material after placing the steel bar truss and steel mesh and then pouring concrete, resulting in uneven thickness of the sound-insulating surface layer and difficulty in scraping the sound-insulating surface layer at the position of the steel bar truss. In addition, spraying the sound-insulating isolation layer material on the steel bar truss can, on the one hand, form a sound-insulating isolation layer that completely covers the exposed steel bar truss; on the other hand, when spraying the sound-insulating isolation layer material, it can fill the blank areas or weak areas of the sound-insulating surface layer generated when pressing the steel bar truss, making the sound-insulating interface more complete and ensuring the sound-insulating performance of the entire flexible sound-insulating precast thermal insulation board. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the following drawings are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0018] Figure 1 It is a schematic cross-sectional structure diagram of a preferred embodiment of the flexible sound-insulating precast thermal insulation board described in the present invention; Figure 2 ForFigure 1 Enlarged view of part I.

[0019] 10 - Flexible sound-insulating precast thermal insulation board, 11 - Precast thermal insulation layer, 12 - Steel bar truss, 13 - Steel bar mesh, 14 - Sound-insulating surface layer, 15 - Sound-insulating isolation layer, 16 - Rubber cushion block, 17 - Crack-resistant surface layer, 21 - Reinforcement bars in the cast-in-place layer. Specific embodiments

[0020] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments.

[0021] As Figure 1 、 2 shown, in the preferred embodiment of the flexible sound-insulating precast thermal insulation board of the present invention, it mainly includes a precast thermal insulation layer 11, a steel bar truss 12 embedded in the precast thermal insulation layer, and a steel bar mesh 13 tied to the bottom of the steel bar truss. It also includes a sound-insulating surface layer 14 provided on one side of the precast thermal insulation layer facing the cast-in-place layer, and a sound-insulating isolation layer 15 is coated on the outer surface of the part of the steel bar truss exposed from the precast thermal insulation layer. The precast thermal insulation layer 11 is a flexible lightweight thermal insulation concrete layer, and the flexible lightweight thermal insulation concrete layer is made by mixing lightweight thermal insulation concrete with flexible powder. Among them, the flexible powder can increase the damping coefficient of the precast thermal insulation layer 11 for sound conduction, so that sound waves generate energy exchange in the flexible powder, thereby consuming the transmission energy of the sound waves and further improving the sound insulation performance of the flexible sound-insulating precast thermal insulation board. The flexible lightweight thermal insulation concrete is preferably made by mixing modified polystyrene particle concrete with graphite or rubber powder. On the one hand, the modified polystyrene particle concrete can ensure the thermal insulation performance of the flexible sound-insulating precast thermal insulation board. On the other hand, graphite or rubber powder can ensure that the flexible sound-insulating precast thermal insulation board has a certain elastic modulus, thereby improving its sound insulation performance. At the same time, this combination can meet the mechanical properties required by the precast thermal insulation board as the bottom plate of the composite floor slab in terms of structure.

[0022] In this preferred embodiment, it is preferably set that the sound-insulating surface layer is a cement-based sound-insulating coating layer, which is convenient for attaching the sound-insulating slurry to the side of the precast thermal insulation layer facing the cast-in-place layer by scraping or spraying during the production of the precast thermal insulation board. The cement-based sound-insulating coating is mainly composed of cement, rubber powder, mica powder, emulsion, etc. Its absorption coefficient for sound waves around 1000 Hz is ≥0.85, which can effectively block the transmission of sound and improve the sound insulation effect of the entire flexible sound-insulating precast thermal insulation board.

[0023] In this preferred embodiment, preferably, a sound insulation and isolation layer 15 is coated on the outer surface of the part of the steel bar truss 12 that exposes the precast thermal insulation layer. The material of the sound insulation and isolation layer can be selected according to needs, such as rubber, foam plastic and other materials, and it is closely adhered to the surface of the steel bar truss by means of pasting. In this preferred embodiment, preferably, the sound insulation and isolation layer is made of the same material as the above-mentioned sound insulation surface layer, that is, cement-based sound insulation coating, and it can be evenly coated on the outer surface of the part of the truss steel bar that exposes the precast thermal insulation layer by using spraying equipment.

[0024] In the above embodiment, preferably, rubber cushion blocks 16 are arranged between the steel bar truss and the steel bar mesh, and preferably, rubber cushion blocks 16 are also arranged between the steel bar mesh and the side surface of the precast thermal insulation layer away from the cast-in-place layer. The position and quantity of the rubber cushion blocks are determined according to the distribution of the truss and the area of the steel bar mesh.

[0025] In the above embodiment, preferably, a crack-resistant surface layer 17 is arranged on the side of the precast thermal insulation layer of the precast thermal insulation board away from the cast-in-place layer, and the crack-resistant surface layer 17 is formed by a combination of polymer cement and mesh cloth.

[0026] In the preferred embodiment of the production method of the flexible sound insulation precast thermal insulation board of the present invention, it mainly includes the following steps: S10. Prepare lightweight thermal insulation concrete, mix in flexible powder and stir evenly to form flexible lightweight thermal insulation concrete; prepare the materials required for the sound insulation surface layer and the sound insulation and isolation layer; S20. Cut the steel bar mesh according to the size of the flexible sound insulation precast thermal insulation board, and tie the steel bar truss to the steel bar mesh at the preset position; S30. Install the mold according to the size of the flexible sound insulation precast thermal insulation board, clean the template surface, and evenly spray the release agent; S40. Pour the flexible lightweight thermal insulation concrete prepared in the step S10 into the mold according to the preset thickness and level it to form a flexible lightweight thermal insulation concrete layer; S50. Evenly scrape the sound insulation surface layer material prepared in the step S10 on the surface of the flexible lightweight thermal insulation concrete layer formed in S30, and ensure that the thickness meets the preset requirements; S60. Press the combined steel bar truss and steel bar mesh in the step S20 into the flexible lightweight thermal insulation concrete layer, and vibrate the bottom of the mold synchronously when pressing; S70. Spray the sound insulation and isolation layer material prepared in the step S10 on the steel bar truss to form a sound insulation and isolation layer, and ensure that its thickness meets the preset requirements; S80. Cure and form.

[0027] In step S10, according to the design requirements, various raw materials of the lightweight thermal insulation concrete are accurately measured, mixed with flexible powder and stirred evenly. Specifically, in this preferred embodiment, the lightweight thermal insulation concrete uses modified polystyrene particle concrete, and its raw materials include cement, aggregate, modified polystyrene particles, polymer emulsion, etc. The flexible powder is selected from graphite or rubber or a mixture of graphite and rubber. The measured raw materials are sequentially added to the mixing equipment and stirred according to the set mixing procedure. During the stirring process, observe the slump of the concrete and control its slump at 160 ± 20 mm by adjusting the water consumption and other methods. After stirring evenly, it is reserved for use. In this preferred embodiment, the sound insulation surface layer and the sound insulation isolation layer use the same material, preferably a cement-based sound insulation coating. Specifically, the raw materials of the cement-based sound insulation coating are preferably cement, rubber powder, mica powder, emulsion, etc. Each accurately measured raw material is fully stirred according to the preset ratio and introduced into the spraying equipment.

[0028] In step S20, the steel mesh is cut according to the preset size, and the steel truss is tied to the steel mesh at the preset position. Specifically, according to the drawing size, use steel processing equipment to accurately cut the steel mesh and the truss, and perform pretreatment such as rust removal and straightening. In this preferred embodiment, step S20 also includes tying rubber pads between the steel truss and the steel mesh, and rubber pads can also be tied to the bottom of the steel mesh according to needs.

[0029] In step S30, install the mold according to the preset size, clean the template surface, and evenly spray the release agent. Specifically, according to the designed slab size, use professional mold installation equipment to accurately install the mold. After installation, use a high-pressure air spray gun or other suitable tools to thoroughly clean the template surface to ensure that there are no impurities such as oil stains and dust on the template surface. Then, use the spraying equipment to evenly spray the water-based silicone release agent, and ensure that the release agent evenly covers the template surface by controlling the spraying pressure, distance and speed.

[0030] In this preferred embodiment, after step S30, step S31 is further included. Polymer cement with a preset thickness is evenly spread in the mold, and then a grid cloth is fully laid to form a crack-resistant surface layer. Specifically, the polymer cement and water are fully stirred, and the stirring time is determined according to the equipment performance and material characteristics to ensure that the polymer cement slurry is uniform and free of lumps. The stirred polymer cement slurry is evenly scraped on the inner surface of the mold through a plastering machine or a manual trowel to form a 3-mm-thick polymer cement crack-resistant mortar layer. During the spreading process, a flatness detection tool is used for real-time detection to ensure that the thickness of the polymer cement crack-resistant mortar layer is uniform and there is no phenomenon of local over-thickness or under-thickness. At the same time, the initial setting time of the polymer cement layer is recorded to ensure that the initial setting time ≥ 45 min. The grid cloth is cut according to the mold size to ensure that the grid cloth size is slightly larger than the inner surface size of the mold. Before the polymer cement layer starts to set, the cut grid cloth is laid flat on the polymer cement layer, and a scraper is used to gently scrape the grid cloth to make the grid cloth closely fit the polymer cement layer, and the air between the grid cloth and the polymer cement layer is squeezed out to avoid wrinkles and hollowing, thereby forming a crack-resistant layer.

[0031] In step S40, a concrete conveying device is used to slowly pour the flexible lightweight thermal insulation concrete prepared in step S10 into the mold. During the pouring process, a vibrating device is used to appropriately vibrate the mold to make the concrete evenly distributed and remove the internal air bubbles. After the pouring is completed, a troweling machine or manual labor is used to level the surface of the concrete to ensure that the surface flatness meets the requirements, forming a flexible lightweight thermal insulation concrete layer.

[0032] In step S50, the sound insulation surface layer material prepared in step S10 is poured into a scraping device, and starting from one end of the mold, the sound insulation surface layer material is evenly scraped on the surface of the flexible lightweight thermal insulation concrete layer, and the scraping thickness is controlled between 3 mm and 5 mm. During the scraping process, a thickness detection tool is used for real-time detection to ensure that the coating thickness is uniform.

[0033] In step S60, before the flexible lightweight thermal insulation concrete layer reaches the initial setting (determined according to the concrete performance and environmental conditions), the steel bar truss and steel bar mesh tied in step S20 are pressed down from the upper surface of the flexible lightweight thermal insulation concrete layer, and at the same time, the vibrating device at the bottom of the mold is started. Through vibration, the steel bar truss and steel bar mesh can quickly enter the concrete layer and better combine with the concrete. During the pressing process, observe the position and verticality of the steel bar mesh truss to ensure that it meets the design requirements.

[0034] In step S70, pour the sound insulation and isolation layer coating prepared in step S10 into the spraying equipment, adjust the pressure, nozzle size and angle of the spraying equipment, control the nozzle height to be no more than 100 mm from the top of the steel bar truss, and spray evenly back and forth 2 - 3 times, with an appropriate interval between each spraying to allow the previous layer of coating to have a certain drying time. By controlling the number of sprays and the speed, control the thickness of the sound insulation and isolation layer between 2 mm and 3 mm. As needed, the nozzle can also be moved to align with the sound insulation surface layer under the steel bar truss to supplement the spraying of blank areas or areas with lower thickness. After spraying is completed, conduct an appearance inspection on the sound insulation and isolation layer to ensure that the surface is uniform, without missed spraying, sagging and other phenomena.

[0035] Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts, any modifications, equivalent replacements, improvements, etc., shall be included in the protection scope of the present invention.

Claims

1. A flexible sound-insulating prefabricated thermal insulation board, characterized in that, It includes a prefabricated thermal insulation layer, a steel bar truss embedded in the prefabricated thermal insulation layer, and a steel bar mesh tied to the bottom of the steel bar truss. A sound insulation surface layer is provided on one side of the prefabricated thermal insulation layer facing the cast-in-place layer. The outer surface of the part of the steel bar truss exposed from the prefabricated thermal insulation layer is coated with a sound insulation isolation layer. The prefabricated thermal insulation layer is a flexible lightweight thermal insulation concrete layer, and the flexible lightweight thermal insulation concrete layer is made by mixing lightweight thermal insulation concrete with flexible powder.

2. The flexible sound-insulating prefabricated thermal insulation board according to claim 1, characterized in that, The lightweight thermal insulation concrete is modified polystyrene particle concrete, and the flexible powder is graphite or rubber powder.

3. The flexible sound-insulating prefabricated thermal insulation board according to claim 1, characterized in that, A rubber cushion block is provided between the steel bar truss and the steel bar mesh.

4. The flexible sound-insulating prefabricated thermal insulation board according to claim 3, wherein A rubber cushion block is provided between the steel bar mesh and the side surface of the prefabricated thermal insulation layer away from the cast-in-place layer.

5. The flexible sound-insulating prefabricated thermal insulation board according to claim 1, characterized in that, The sound insulation surface layer is a cement-based sound insulation coating layer.

6. The flexible sound-insulating prefabricated thermal insulation board according to any one of claims 1 to 5, characterized in that An anti-cracking surface layer is provided on the side of the prefabricated thermal insulation layer of the prefabricated thermal insulation board away from the cast-in-place layer.

7. A production method of the flexible sound-insulating prefabricated thermal insulation board as described in claim 1, characterized in that, It includes the following steps: S10. Prepare the lightweight thermal insulation concrete, mix in the flexible powder and stir evenly to form the flexible lightweight thermal insulation concrete; Prepare the materials required for the sound insulation surface layer and the sound insulation isolation layer; S20. Cut the steel bar mesh according to the size of the flexible sound insulation prefabricated thermal insulation board, and tie the steel bar truss to the steel bar mesh at the preset position; S30. Install the mold according to the size of the flexible sound insulation prefabricated thermal insulation board, clean the template surface, and evenly spray the release agent; S40. Pour the flexible lightweight thermal insulation concrete prepared in step S10 into the mold according to the preset thickness and level it to form a flexible lightweight thermal insulation concrete layer; S50. Evenly scrape the sound insulation surface layer material prepared in step S10 on the surface of the flexible lightweight thermal insulation concrete layer formed in S30, and ensure that the thickness meets the preset requirements; S60. Press the combined steel bar truss and steel bar mesh in step S20 into the flexible lightweight thermal insulation concrete layer, and vibrate the bottom of the mold synchronously during pressing; S70. Spray the sound insulation isolation layer material prepared in step S10 on the steel bar truss to form a sound insulation isolation layer, and ensure that its thickness meets the preset requirements; S80. Cure and form.

8. The production method of the flexible sound-insulating prefabricated thermal insulation board according to claim 7, characterized in that, In step S20, it also includes tying a rubber cushion block between the steel bar truss and the steel bar mesh.

9. The production method of the flexible sound-insulating prefabricated thermal insulation board according to claim 7, characterized in that, After step 30, the following steps are also included: S31. Evenly scrape a high-polymer cement anti-cracking mortar with a preset thickness in the mold, and then fully lay the grid cloth to form an anti-cracking surface layer.

Images