Flexible soundproof prefabricated thermal insulation panel and method for producing the same

Abstract

The application 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 mesh sheet bound at the bottom of the steel bar truss, a sound insulation surface layer is arranged on the side of the prefabricated insulation layer facing a cast-in-place layer, the outer surface of the part of the steel bar truss exposed from the prefabricated insulation layer is coated with a sound insulation isolation layer, the prefabricated insulation layer is a flexible lightweight thermal insulation concrete layer, and the flexible lightweight thermal insulation concrete layer is made of lightweight thermal insulation concrete mixed with flexible powder. By arranging the prefabricated insulation layer as the flexible lightweight thermal insulation concrete layer, the consumption of sound wave energy by the prefabricated insulation layer 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 insulation layer and the cast-in-place layer of the floor slab, the continuous transmission of sound waves is effectively blocked, the generation of sound bridges is prevented, and the sound insulation performance of the flexible sound insulation prefabricated insulation board and the floor slab to which the flexible sound insulation prefabricated insulation board is applied is greatly improved. The application further discloses a production method of the flexible sound insulation prefabricated insulation board.

Description

Technical Field

[0001] This invention relates to the field of prefabricated building technology, and in particular to a flexible sound-insulating prefabricated insulation board and its production method. Background Technology

[0002] In existing prefabricated buildings, the floor slabs mainly adopt insulated composite floor slabs, which include prefabricated insulation boards made of insulated concrete materials and cast-in-place floor layers stacked on the prefabricated insulation boards. The steel trusses embedded in the prefabricated insulation boards form a rigid connection with the cast-in-place floor layers. The vibration of the floor slab can be easily transmitted to the prefabricated insulation boards or other structural parts of the floor slab through the steel trusses, thus forming a sound bridge. Usually, the prefabricated insulation boards are placed as porous elastic layers under the floor slabs, which have a certain sound absorption effect, but have little effect on blocking impact sound.

[0003] Currently, the sound insulation and noise reduction treatment of insulated composite floor slabs on the market mainly involves stacking a cast-in-place layer on a precast insulation slab as a structural layer. After the cast-in-place layer is formed, a sound insulation layer and a protective layer are added in sequence, resulting in an increase in structural thickness and a decrease in building height. At the same time, the on-site construction process is increased, which not only makes the construction process more complicated, but also increases the difficulty and cost of construction management. Summary of the Invention

[0004] The present invention aims to provide a flexible prefabricated sound insulation board that, while ensuring the thermal insulation performance of the floor, comprehensively improves the sound insulation performance of the floor system, and overcomes the problems of complex construction, increased thickness, and sound bridging of existing prefabricated insulation boards.

[0005] To achieve the above objectives, the technical solution of the present invention is as follows: a flexible sound-insulating prefabricated insulation board is constructed, comprising a prefabricated insulation layer, a steel truss embedded in the prefabricated insulation layer, and a steel mesh tied to the bottom of the steel truss. The side of the prefabricated insulation layer facing the cast-in-place layer is provided with a sound-insulating surface layer. The outer surface of the portion of the steel truss exposed above the prefabricated insulation layer is covered with a sound-insulating layer. The prefabricated insulation layer is a flexible lightweight insulating concrete layer, which is made by mixing lightweight insulating concrete with flexible powder.

[0006] Furthermore, the lightweight insulating 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 density.

[0007] Furthermore, rubber pads are provided between the steel truss and the steel mesh; the rubber pads can effectively cut off sound bridges, reduce structural sound transmission, and further improve the sound insulation performance of the precast insulation board.

[0008] Furthermore, a rubber pad is provided between the steel mesh and the side of the precast 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 insulation layer and cast-in-place concrete, ensuring the integrity of the floor slab structure.

[0010] Furthermore, the prefabricated insulation layer of the prefabricated insulation board is provided with a crack-resistant surface layer on the side away from the cast-in-place layer; this further enhances the tensile strength and crack resistance of the prefabricated insulation board and improves the overall structural stability of the prefabricated insulation board.

[0011] Another technical problem to be solved by the present invention is to provide a production method for a flexible sound-insulating prefabricated insulation board, so as to ensure that the above-mentioned flexible sound-insulating prefabricated insulation board can be mass-produced.

[0012] The technical solution of this invention to solve another technical problem is: a method for producing a flexible sound-insulating prefabricated insulation board as described above, comprising 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 sound insulation surface layer and sound insulation isolation layer. S20. Cut the steel mesh according to the size of the flexible sound insulation prefabricated insulation board, and tie the steel truss to the steel mesh according to the preset position; S30. Install the mold according to the dimensions of the flexible sound insulation prefabricated insulation board, clean the mold surface, and spray the release agent evenly; S40. Pour the flexible lightweight thermal insulation concrete prepared in step S10 into the mold according to the preset thickness and smooth it to form a flexible lightweight thermal insulation concrete layer. S50. The sound insulation surface material prepared in step S10 is evenly scraped onto the surface of the flexible lightweight thermal insulation concrete layer formed in S30, and the thickness is ensured to meet the preset requirements. S60. Press the assembled steel truss and steel mesh from step S20 into the flexible lightweight thermal insulation concrete layer, and simultaneously vibrate the bottom of the mold during pressing. S70. Spray the sound insulation material prepared in step S10 onto the steel truss to form a sound insulation layer, and ensure that its thickness meets the preset requirements; S80. Curing and shaping.

[0013] Furthermore, step S20 also includes binding rubber pads between the steel truss and the steel mesh.

[0014] Furthermore, step 30 is followed by the following steps: S31. Evenly spread polymer cement of a predetermined thickness in the mold, and then fully cover it with mesh cloth to form a crack-resistant surface layer.

[0015] The flexible sound-insulating precast insulation board and its production method of the present invention have the following beneficial effects: By setting a sound-insulating surface layer on the side of the precast insulation layer facing the cast-in-place layer, this sound-insulating surface layer forms a sound-insulating interface between the precast insulation board and the cast-in-place layer, which can effectively block the continuous transmission of sound waves, thereby effectively improving the sound insulation performance of the entire floor slab; by covering the exposed steel truss with a sound-insulating isolation layer, a layer of sound-insulating material is separated between the steel truss and the cast-in-place concrete of the floor slab, completely blocking the sound bridge generated by the steel truss within the insulated floor slab, further improving the sound insulation performance of the entire floor slab. By setting the precast insulation layer as a flexible lightweight insulating concrete layer, which is made by mixing lightweight insulating concrete with flexible powder, the flexible powder can increase the damping coefficient of the precast insulation layer for sound transmission, so that sound waves exchange energy in the flexible powder, thereby consuming the transmission energy of sound waves, further improving the sound insulation performance of the precast insulation board. Furthermore, the sound insulation interface and sound insulation layer can be completed in the factory, resulting in more stable overall quality, reduced on-site construction procedures, and a significant reduction in material usage. This flexible prefabricated sound insulation board improves sound insulation performance while maintaining the original thermal insulation performance, without increasing the overall thickness of the floor slab, thus broadening its application range.

[0016] The production method involves first pouring flexible lightweight insulating concrete into a mold to form a flexible lightweight insulating concrete layer, then applying a sound-insulating surface material to the surface. The assembled steel truss and steel mesh are then pressed into the flexible lightweight insulating concrete layer. Simultaneously, the bottom of the mold is vibrated during pressing, greatly protecting the integrity of the sound-insulating surface layer. This avoids the problems of uneven sound-insulating surface layer thickness and difficulty in applying the sound-insulating surface material at the steel truss locations, which are often caused by placing the steel truss and steel mesh first and then pouring concrete. Furthermore, spraying the sound-insulating layer material onto the steel truss creates a sound-insulating layer that completely covers the exposed steel truss. Additionally, the spraying process fills in any gaps or weak areas in the sound-insulating surface layer created during the pressing of the steel truss, resulting in a more complete sound insulation interface and ensuring the overall sound insulation performance of the flexible precast sound-insulating panel. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a cross-sectional structural diagram of a preferred embodiment of the flexible sound insulation prefabricated insulation board of the present invention; Figure 2 for Figure 1 Enlarged view of part I.

[0019] 10-Flexible sound insulation prefabricated insulation board, 11-Prefabricated insulation layer, 12-Steel truss, 13-Steel mesh, 14-Sound insulation surface layer, 15-Sound insulation isolation layer, 16-Rubber pad, 17-Crack-resistant surface layer. Detailed Implementation

[0020] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0021] like Figure 1 , 2 As shown, in a preferred embodiment of the flexible sound-insulating prefabricated insulation board of the present invention, it mainly includes a prefabricated insulation layer 11, a steel truss 12 embedded in the prefabricated insulation layer, and a steel mesh 13 tied to the bottom of the steel truss. It also includes a sound-insulating surface layer 14 disposed on the side of the prefabricated insulation layer facing the cast-in-place layer. The outer surface of the portion of the steel truss exposed above the prefabricated insulation layer is covered with a sound-insulating layer 15. The prefabricated insulation layer 11 is a flexible lightweight insulating concrete layer, which is made by mixing lightweight insulating concrete with flexible powder. The flexible powder can increase the damping coefficient of the prefabricated insulation layer 11 for sound transmission, causing energy exchange in the sound waves within the flexible powder, thereby consuming the transmitted energy of the sound waves and further improving the sound insulation performance of the flexible sound-insulating prefabricated insulation board. Flexible lightweight thermal insulation concrete is preferably made of modified polystyrene particle concrete mixed with graphite or rubber powder. On the one hand, the modified polystyrene particle concrete can ensure the thermal insulation performance of the flexible sound insulation precast insulation board. On the other hand, the graphite or rubber powder can ensure that the flexible sound insulation precast insulation board has a certain elastic modulus, thereby improving its sound insulation performance. At the same time, this combination can meet the mechanical performance requirements of the precast insulation board as the base plate of the composite floor slab.

[0022] In this preferred embodiment, the sound insulation surface layer is preferably a cement-based sound insulation coating layer, which facilitates the application of the sound insulation slurry to the side of the precast insulation layer facing the cast-in-place layer during the production of the precast insulation board by scraping or spraying. The cement-based sound insulation coating is mainly composed of cement, rubber powder, mica powder, and emulsion, and has an absorption coefficient ≥0.85 for sound waves around 1000Hz, effectively blocking sound propagation and improving the overall sound insulation effect of the flexible sound-insulating precast insulation board.

[0023] In this preferred embodiment, a sound insulation layer 15 is preferably applied to the outer surface of the portion of the steel truss 12 exposed from the prefabricated insulation layer. The material of the sound insulation layer, such as rubber or foam plastic, can be selected as needed and applied tightly to the surface of the steel truss using an adhesive method. In this preferred embodiment, the sound insulation layer is preferably made of the same material as the aforementioned sound insulation surface layer, i.e., cement-based sound insulation coating, which can be evenly applied to the outer surface of the portion of the truss steel exposed from the prefabricated insulation layer using a spraying device.

[0024] In the above embodiments, it is preferable to provide rubber pads 16 between the steel truss and the steel mesh, and even more preferably, rubber pads 16 are also provided between the steel mesh and the side of the precast insulation layer away from the cast-in-place layer. The position and number of rubber pads are determined according to the distribution of the truss and the area of ​​the steel mesh.

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

[0026] In a preferred embodiment of the production method of the flexible sound-insulating prefabricated insulation board of the present invention, the main steps include: 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 sound insulation surface layer and sound insulation isolation layer. S20. Cut the steel mesh according to the size of the flexible sound insulation prefabricated insulation board, and tie the steel truss to the steel mesh according to the preset position; S30. Install the mold according to the dimensions of the flexible sound insulation prefabricated insulation board, clean the mold surface, and spray the release agent evenly; S40. Pour the flexible lightweight thermal insulation concrete prepared in step S10 into the mold according to the preset thickness and smooth it to form a flexible lightweight thermal insulation concrete layer. S50. The sound insulation surface material prepared in step S10 is evenly scraped onto the surface of the flexible lightweight thermal insulation concrete layer formed in S30, and the thickness is ensured to meet the preset requirements. S60. Press the assembled steel truss and steel mesh from step S20 into the flexible lightweight thermal insulation concrete layer, and simultaneously vibrate the bottom of the mold during pressing. S70. Spray the sound insulation material prepared in step S10 onto the steel truss to form a sound insulation layer, and ensure that its thickness meets the preset requirements; S80. Curing and shaping.

[0027] In step S10, according to 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 is modified polystyrene particle concrete, whose raw materials include cement, aggregate, modified polystyrene particles, polymer emulsion, etc., and the flexible powder is selected from graphite, rubber, or a mixture of graphite and rubber. The measured raw materials are added to the mixing equipment in sequence and mixed according to the set mixing program. During the mixing process, the slump of the concrete is observed, and by adjusting the water volume, the slump is preferably controlled at 160 ± 20 mm. After being stirred evenly, it is set aside for later use. In this preferred embodiment, the sound insulation surface layer and the sound insulation isolation layer use the same material, preferably 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., and the accurately measured raw materials are thoroughly mixed according to the preset ratio and introduced into the spraying equipment.

[0028] In step S20, the steel mesh is cut to a preset size, and the steel truss is tied to the steel mesh at a preset position. Specifically, the steel mesh and truss are accurately cut using steel processing equipment according to the dimensions in the drawings, and pre-treatment such as rust removal and straightening is performed. 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 as needed.

[0029] In step S30, the mold is installed according to the preset dimensions, the mold surface is cleaned, and a release agent is sprayed evenly. Specifically, according to the designed board dimensions, professional mold installation equipment is used to accurately install the mold. After installation, a high-pressure air spray gun or other suitable tools are used to thoroughly clean the mold surface to ensure that there are no oil stains, dust, or other impurities on the mold surface. Then, a water-based silicone release agent is sprayed evenly using a spraying device. By controlling the spraying pressure, distance, and speed, it is ensured that the release agent evenly covers the mold surface.

[0030] In this preferred embodiment, step S30 is followed by step S31: a pre-set thickness of polymer cement is evenly spread within the mold, and then a mesh fabric is laid to form a crack-resistant surface layer. Specifically, the polymer cement and water are thoroughly mixed, with the mixing time determined based on equipment performance and material characteristics to ensure the polymer cement slurry is uniform and free of lumps. The mixed polymer cement slurry is evenly spread onto the inner surface of the mold using a trowel or manual trowel to form a 3mm thick polymer cement crack-resistant mortar layer. During the spreading process, a flatness testing tool is used to check in real time to ensure the polymer cement crack-resistant mortar layer has a uniform thickness, without any localized areas that are too thick or too thin. Simultaneously, the initial setting time of the polymer cement layer is recorded to ensure it is ≥45 minutes. The mesh fabric is cut to the mold dimensions, ensuring the mesh fabric size is slightly larger than the inner surface dimensions of the mold. Before the polymer cement layer initially sets, lay the cut mesh fabric flat on the polymer cement layer, and use a scraper to gently scrape the mesh fabric to make it adhere tightly to the polymer cement layer, squeezing out the air between the mesh fabric and the polymer cement layer, avoiding wrinkles and hollows, thus forming a crack-resistant layer.

[0031] In step S40, the flexible lightweight insulating concrete prepared in step S10 is slowly poured into the mold using concrete conveying equipment. During the pouring process, the mold is appropriately vibrated using vibration equipment to ensure even distribution of the concrete and to remove internal air bubbles. After pouring, the concrete surface is smoothed using a power trowel or manually to ensure that the surface flatness meets the requirements, thus forming a flexible lightweight insulating concrete layer.

[0032] In step S50, the sound insulation surface material prepared in step S10 is poured into the coating equipment. Starting from one end of the mold, the sound insulation surface material is evenly coated onto the surface of the flexible lightweight thermal insulation concrete layer, controlling the coating thickness to be between 3mm and 5mm. During the coating process, a thickness detection tool is used to monitor the thickness in real time to ensure uniform coating thickness.

[0033] In step S60, before the flexible lightweight insulating concrete layer reaches its initial set (determined based on concrete properties and environmental conditions), the steel truss and steel mesh tied in step S20 are pressed downwards from the upper surface of the flexible lightweight insulating concrete layer. Simultaneously, the vibration device at the bottom of the mold is activated, allowing the steel truss and steel mesh to quickly penetrate the concrete layer and better bond with it. During the pressing process, the position and verticality of the steel mesh truss are observed to ensure they meet design requirements.

[0034] In step S70, the sound insulation coating prepared in step S10 is poured into the spraying equipment. The pressure, nozzle size, and angle of the spraying equipment are adjusted, and the nozzle height is controlled to be no more than 100mm from the top of the steel truss. The coating is sprayed evenly back and forth 2-3 times, with appropriate intervals between each spray to allow the previous layer of coating sufficient drying time. By controlling the number of sprays and the speed, the thickness of the sound insulation layer is controlled between 2mm and 3mm. If necessary, the nozzle can be moved to aim at the sound insulation surface below the steel truss to supplement the coating in blank areas or areas with lower thickness. After spraying, the sound insulation layer is visually inspected to ensure a uniform surface without any missed areas or runs.

[0035] Based on the embodiments of the present invention, any modifications, equivalent substitutions, improvements, etc., made by all other embodiments obtained by those skilled in the art without creative effort should be included within the protection scope of the present invention.

Claims

1. A flexible prefabricated sound insulation board, characterized in that, The system includes a precast insulation layer, a steel truss embedded in the precast insulation layer, and a steel mesh tied to the bottom of the steel truss. The side of the precast insulation layer facing the cast-in-place layer is provided with a sound insulation surface layer. The outer surface of the portion of the steel truss exposed above the precast insulation layer is covered with a sound insulation layer. The precast insulation layer is a flexible lightweight insulating concrete layer, which is made by mixing lightweight insulating concrete with flexible powder. The lightweight insulating concrete is modified polystyrene particle concrete, and the flexible powder is graphite or rubber powder. The sound insulation surface layer is a cement-based sound insulation coating layer, and the sound insulation layer is a cement-based sound insulation coating layer.

2. The flexible sound-insulating prefabricated insulation board according to claim 1, characterized in that, Rubber pads are provided between the steel truss and the steel mesh.

3. The flexible sound-insulating prefabricated insulation board according to claim 2, characterized in that, A rubber pad is provided between the steel mesh and the side of the precast insulation layer away from the cast-in-place layer.

4. The flexible sound-insulating prefabricated insulation board according to any one of claims 1 to 3, characterized in that, The prefabricated insulation layer of the prefabricated insulation board has a crack-resistant surface layer on the side away from the cast-in-place layer.

5. A method for producing a flexible sound-insulating prefabricated thermal insulation board as described in claim 1, characterized in that, Includes the following steps: S10. Prepare lightweight thermal insulation concrete by mixing in flexible powder and stirring evenly to form flexible lightweight thermal insulation concrete. Prepare the materials required for the sound insulation surface layer and sound insulation isolation layer; S20. Cut the steel mesh according to the size of the flexible sound insulation prefabricated insulation board, and tie the steel truss to the steel mesh according to the preset position; S30. Install the mold according to the dimensions of the flexible sound insulation prefabricated insulation board, clean the mold surface, and spray the release agent evenly; S40. Pour the flexible lightweight thermal insulation concrete prepared in step S10 into the mold according to the preset thickness and smooth it to form a flexible lightweight thermal insulation concrete layer. S50. The sound insulation surface material prepared in step S10 is evenly scraped onto the surface of the flexible lightweight thermal insulation concrete layer formed in S40, and the thickness is ensured to meet the preset requirements. S60. Press the assembled steel truss and steel mesh from step S20 into the flexible lightweight thermal insulation concrete layer, and simultaneously vibrate the bottom of the mold during pressing. S70. Spray the sound insulation material prepared in step S10 onto the steel truss to form a sound insulation layer, and ensure that its thickness meets the preset requirements; S80. Curing and shaping.

6. The method for producing the flexible sound-insulating prefabricated insulation board according to claim 5, characterized in that, Step S20 also includes binding rubber pads between the steel truss and the steel mesh.

7. The method for producing the flexible sound-insulating prefabricated thermal insulation board according to claim 5, characterized in that, The following steps are included after step S30: S31. Apply a pre-set thickness of polymer cement crack-resistant mortar evenly inside the mold, and then fully cover it with mesh cloth to form a crack-resistant surface layer.

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