Three-layer sound insulation system for sound insulation of ceramic tile surface layer floor

Abstract

The invention relates to a three-layer sound insulation system for sound insulation of a ceramic tile surface layer floor, which is arranged between a concrete floor and a ceramic tile surface layer and comprises a low-elasticity-modulus lower layer material, a high-elasticity-modulus middle layer material and a low-elasticity-modulus sound insulation ceramic tile adhesive which are sequentially arranged from bottom to top, and a'strong-weak-strong-weak-strong 'sandwich structure made of five layers of materials with different elastic moduli is formed by the sandwich layer, a concrete floor and a ceramic tile surface layer. When the ceramic tiles are used as the decorative layer, the sound insulation index can reach more than 15dB, the use requirements of common residences can be met, an elastic body sound insulation layer does not need to be additionally arranged, and the construction procedures and the project cost are reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of sound insulation, in particular to a three-layer sound insulation system for sound insulation of a tile surface floor. Background Art

[0002] With the rapid development of high-rise buildings in recent years, the requirements for floor sound insulation have become increasingly stringent. The "Residential Project Code" (GB 55038-2025) specifies impact sound insulation requirements for individual floor slabs, requiring the weighted normalized impact sound pressure level for bedroom and living room floors to be no greater than 65 decibels. This mandatory engineering construction code must be strictly enforced.

[0003] Currently, floor sound insulation primarily utilizes floating floor technology. The floating floor structure is shown in Figure 1. Specifically, from bottom to top, it comprises a structural layer (reinforced concrete floor 1) → an elastic vibration damping layer 6 (elastic material layer) → a floating slab layer 7 (fine aggregate concrete layer with steel mesh). Common elastic vibration damping layers include sound insulation pads, sound insulation mortar, and sound insulation coatings. Finally, a decorative layer such as ceramic tiles is laid atop the floating slab. Only the sound insulation pads can easily achieve the weighted normalized impact sound pressure level requirement of no more than 65 decibels.

[0004] Sound insulation mats are organically produced rolls, typically 3-20mm thick and providing a sound insulation rating of 15-30 dB. They are weak, requiring a surface layer of 40-50mm fine-stone concrete (strength grade no less than C25) with steel mesh. They are also prone to hollowing and cracking over long periods of use. In recent years, organic insulation boards have also been used as an alternative to sound insulation mats.

[0005] The method of using sound insulation pads can effectively improve the sound insulation performance of floor slabs, but it also has the following disadvantages.

[0006] (1) A separate elastomer sound insulation layer is added, which increases the construction process and project cost.

[0007] (2) Since the strength and elastic modulus of the above-mentioned elastomer materials are very low, a thicker leveling layer must be used. When the floor height is fixed, the net height of the room is reduced, affecting the living experience; and the surface is prone to cracking after long-term use.

[0008] (3) Because it contains organic components, its combustion performance is usually Class B, the material testing is complicated, and there is a fire risk during construction and use.

[0009] To solve this problem, Chinese patent ZL 202111169681.0 proposes a double-layer gypsum mortar sound insulation system with higher sound insulation performance. It consists of a higher-strength gypsum mortar surface layer and a lower-strength cushion layer. When ceramic tiles are used as the decorative layer, the sound insulation can reach more than 10dB, which can meet the requirement of the weighted standardized impact sound pressure level of no more than 70 dB in the original standard. However, the sound insulation performance is difficult to meet the requirement of the new standard of no more than 65 dB in the weighted standardized impact sound pressure level. Summary of the Invention

[0010] In response to the problems existing in the prior art, the purpose of the present invention is to provide a three-layer sound insulation system for sound insulation of tile-surfaced floors, which can further improve the sound insulation capacity of the floor system and make the sound insulation performance meet the requirements of the weighted standardized impact sound pressure level in the new standard.

[0011] In order to achieve the above object, the present invention adopts the following technical solutions: A three-layer sound insulation system for sound insulation of a tile surface floor, arranged between a concrete floor and a tile surface layer, comprising a low elastic modulus lower layer material, a high elastic modulus middle layer material, and a low elastic modulus sound insulation ceramic tile adhesive arranged in sequence from bottom to top; The 28d elastic modulus of the low elastic modulus lower layer material is not greater than 2.0GPa, and the thickness is 10~25mm; the 28d elastic modulus of the high elastic modulus middle layer material is 10~45GPa, and the thickness is 10~25mm; the sum of the thicknesses of the low elastic modulus lower layer material and the high elastic modulus middle layer material is less than 40mm; the 28d elastic modulus of the low elastic modulus sound insulation ceramic tile adhesive is not greater than 3.5GPa, and the thickness is 3~10mm.

[0012] Furthermore, the low elastic modulus lower layer material is gypsum mortar using vitrified microspheres as aggregate, and its 28d absolute dry compressive strength is 2.5~12MPa; the high elastic modulus middle layer material is gypsum-based self-leveling mortar, and its 28d absolute dry compressive strength is not less than 20MPa; the low elastic modulus sound insulation ceramic tile adhesive uses vitrified microspheres as aggregate.

[0013] Furthermore, the low elastic modulus lower layer material is gypsum mortar using vitrified microspheres as aggregate, and its 28d absolute dry compressive strength is 2.5~12MPa; the high elastic modulus middle layer material is ultra-high performance concrete, and its 28d compressive strength is not less than 100MPa; the low elastic modulus sound insulation ceramic tile adhesive uses vitrified microspheres as aggregate.

[0014] Furthermore, the low elastic modulus lower layer material is a gypsum mortar using glass beads as aggregate, and flame-retardant polystyrene particles with a particle size of less than 3 mm are used to replace part of the glass beads, with a volume replacement amount of 10% to 70%.

[0015] Furthermore, after the low elastic modulus lower layer material is poured, the glass beads and flame-retardant polystyrene particles therein partially float upward, and after hardening, a layer with more lightweight aggregate is formed on the upper part.

[0016] Furthermore, an interface agent is used between the low elastic modulus lower layer material and the floor slab.

[0017] Furthermore, the low elastic modulus sound insulation ceramic tile adhesive uses vitrified microspheres as aggregates and is added with at least one of an air entraining agent and a plastic expansion agent to reduce the elastic modulus.

[0018] Furthermore, the low elastic modulus sound insulation ceramic tile adhesive contains the following materials in parts by mass: 30.0 to 50.0 parts of cementitious material, 5.0 to 10.0 parts of closed-cell vitrified microspheres, 0 to 0.3 parts of early strength agent, 0.1 to 0.4 parts of cellulose ether, 1.0 to 5.0 parts of dispersible rubber powder, 0.01 to 0.04 parts of air entraining agent, and 0.01 to 0.06 parts of plastic expansion agent.

[0019] Furthermore, the cementitious materials in the low elastic modulus sound insulation ceramic tile adhesive include cement and mineral admixtures, wherein the mass proportion of the mineral admixtures is 10% to 70%.

[0020] Furthermore, when the high elastic modulus middle layer material is a gypsum-based self-leveling mortar, the tiles are affixed with a low elastic modulus sound insulation ceramic tile adhesive after natural drying and curing for 14 days after pouring.

[0021] The present invention has the following advantages over the prior art: (1) The present invention utilizes three materials with significantly different elastic moduli to form a three-layer sound insulation structure. These materials, along with the concrete floor and tile surface layer, form a sandwich structure of five layers of materials with different elastic moduli, forming a "strong-weak-strong-weak-strong" pattern. This achieves excellent sound insulation. When tiles are used as the decorative layer, the sound insulation can reach over 15 dB, meeting the standard requirement for a weighted standardized impact sound pressure level of no more than 65 dB for general residential buildings. Since no additional elastomeric sound insulation layer is required, construction procedures and project costs are reduced.

[0022] (2) The total structural thickness of the three-layer sound insulation system of the present invention is consistent with the total thickness of the traditional leveling layer and tile adhesive layer, and will not reduce the room headroom and affect the living experience.

[0023] (3) The high elastic modulus middle layer material in the three-layer sound insulation system of the present invention is gypsum-based self-leveling mortar or ultra-high performance concrete, which has high flexural strength, is not prone to hollowing and cracking problems, and has a long service life.

[0024] (4) The structure of the three-layer sound insulation system disclosed in the present invention is mainly composed of inorganic materials, with low fire risk and high safety factor. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is a schematic diagram of the structure of a floating sound insulation floor in the prior art; Figure 2 is a schematic diagram of the reinforced concrete floor slab in Comparative Example 1; Figure 3 Schematic diagram of the structure of Comparative Example 2 and Examples 1-4; The reference numerals are as follows: 1-Reinforced concrete floor slab; 2-Lower layer material; 3-Middle layer material; 4-Ceramic tile adhesive; 5-Ceramic tile; 6-Elastic vibration damping layer; 7-Floating slab layer. DETAILED DESCRIPTION

[0026] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts shall fall within the scope of protection of the present invention.

[0027] Comparative Example 1 Reinforced concrete floor slab 1 is 100mm thick. See the structural diagram Figure 2 .

[0028] Comparative Example 2 The reinforced concrete floor slab 1 is 100mm thick. The lower layer material 2 is gypsum mortar with glass beads as aggregate, with a 28d elastic modulus of 1.8GPa, a 28d absolute compressive strength of 9.5MPa, and a thickness of 15mm. The middle layer material 3 is gypsum-based self-leveling mortar, with a 28d elastic modulus of 11.0GPa, a 28d absolute compressive strength of 22.5MPa, and a thickness of 15mm. The surface layer is decorated with 8mm thick ceramic tiles 5, adhered with 5mm thick ordinary C1 ceramic tile adhesive 4, with a 28d elastic modulus of 5.8GPa. See the structural diagram. Figure 3 .

[0029] Example 1 Reinforced concrete floor slab 1 is 100 mm thick. The lower layer, 2, is 15 mm thick and made of gypsum mortar with vitrified microspheres as the aggregate, boasting a 28-day elastic modulus of 1.8 GPa and a 28-day absolute compressive strength of 9.5 MPa. The middle layer, 3, is 15 mm thick and made of gypsum-based self-leveling mortar, boasting a 28-day elastic modulus of 11.0 GPa and a 28-day absolute compressive strength of 22.5 MPa. The top layer is a decorative layer of 8 mm thick ceramic tiles 5, adhered with a 5 mm thick, low-elastic modulus ceramic tile adhesive 4, with a 28-day elastic modulus of 2.7 GPa. Low elastic modulus sound insulation ceramic tile adhesive 4 contains the following materials by mass: 40.0 parts of cementitious material (including 20.0 parts of ordinary Portland cement and 20.0 parts of mineral admixture), 8.5 parts of closed-cell vitrified microspheres, 0.1 parts of early strength agent, 0.3 parts of cellulose ether, 4.0 parts of dispersible rubber powder, 0.01 parts of air entraining agent, and 0.04 parts of plastic expansion agent. See the structure diagram. Figure 3 .

[0030] Example 2 Reinforced concrete floor slab 1 is 100 mm thick. The lower layer material 2 is gypsum mortar with vitrified microspheres as the aggregate, with a 28-day elastic modulus of 1.7 GPa and a 28-day absolute compressive strength of 9.0 MPa, and a thickness of 15 mm. The middle layer material 3 is gypsum-based self-leveling mortar, with a 28-day elastic modulus of 11.0 GPa, a 28-day absolute compressive strength of 22.5 MPa, and a thickness of 15 mm. The top layer is a decorative layer of 8 mm thick ceramic tiles 5, adhered with a 5 mm thick low-elastic modulus ceramic tile adhesive 4, with a 28-day elastic modulus of 2.7 GPa. The low elastic modulus sound insulation ceramic tile adhesive 4 contains the following materials in parts by mass: 40.0 parts of cementitious material (including 20.0 parts of ordinary Portland cement and 20.0 parts of mineral admixture), 8.5 parts of closed-cell vitrified microspheres, 0.1 parts of early strength agent, 0.3 parts of cellulose ether, 4.0 parts of dispersible rubber powder, 0.01 parts of air entraining agent, and 0.04 parts of plastic expansion agent. After the lower layer material 2 is poured, the vitrified microspheres therein partially float up, and after hardening, a layer with more lightweight aggregate is formed on the upper part. See the structural diagram. Figure 3 .

[0031] Example 3 The reinforced concrete floor 1 is 100 mm thick. The lower layer material 2 is a gypsum mortar with expanded glass beads and particles of flame-retardant polystyrene less than 2 mm in size as aggregate, the volume fraction of expanded glass beads in the aggregate is 50%, the 28d elastic modulus of the mortar is 1.0 GPa, the 28d absolute dry compressive strength is 4.0 MPa, and the thickness is 15 mm; the middle layer material 3 is a gypsum-based self-leveling mortar, the 28d elastic modulus is 11.0 GPa, the 28d absolute dry compressive strength is 22.5 MPa, and the thickness is 15 mm; the surface layer uses an 8 mm thick ceramic tile 5 as a decorative layer, which is pasted with a 5 mm thick low-elasticity modulus ceramic tile adhesive 4, and the 28d elastic modulus of the ceramic tile adhesive is 2.7 GPa. The low-elasticity modulus soundproof ceramic tile adhesive 4 contains the following materials in mass fraction: cementitious materials 40.0 parts (of which ordinary portland cement 20.0 parts, mineral admixtures 20.0 parts), closed expanded glass beads 8.5 parts, early strength agent 0.1 part, cellulose ether 0.3 part, dispersible glue powder 4.0 parts, air entraining agent 0.01 part, and plastic expansion agent 0.04 part. After the lower layer material 2 is poured, the expanded glass beads and flame-retardant polystyrene particles in it partially float up, and a layer with more lightweight aggregate is formed at the upper part after hardening. The structural diagram is shown in Figure 3 .

[0032] Example 4 The reinforced concrete floor 1 is 100 mm thick. The lower layer material 2 is a gypsum mortar with expanded glass beads and particles of flame-retardant polystyrene less than 2 mm in size as aggregate, the volume fraction of expanded glass beads in the aggregate is 50%, the 28d elastic modulus of the mortar is 1.0 GPa, the 28d absolute dry compressive strength is 4.0 MPa, and the thickness is 15 mm; the middle layer material 3 is a gypsum-based self-leveling mortar, the 28d elastic modulus is 11.0 GPa, the 28d absolute dry compressive strength is 22.5 MPa, and the thickness is 15 mm; the surface layer uses an 8 mm thick ceramic tile 5 as a decorative layer, which is pasted with a 5 mm thick low-elasticity modulus ceramic tile adhesive 4, and the 28d elastic modulus of the ceramic tile adhesive is 2.7 GPa. The low-elasticity modulus soundproof ceramic tile adhesive 4 contains the following materials in mass fraction: cementitious materials 40.0 parts (of which ordinary portland cement 20.0 parts, mineral admixtures 20.0 parts), closed expanded glass beads 8.5 parts, early strength agent 0.1 part, cellulose ether 0.3 part, dispersible glue powder 4.0 parts, air entraining agent 0.01 part, and plastic expansion agent 0.04 part. After the lower layer material 2 is poured, the expanded glass beads and flame-retardant polystyrene particles in it partially float up, and a layer with more lightweight aggregate is formed at the upper part after hardening. The structural diagram is shown in Figure 3 .

[0033] In the construction of Comparative Example 2, Example 1, Example 2, and Example 4, the lower layer material 2 is poured first, and the middle layer material 3, a gypsum-based self-leveling mortar, is poured 1d later. After pouring, the structure is naturally dried and cured for 14d, and then the low-elasticity modulus soundproof ceramic tile adhesive 4 is used to paste the ceramic tile 5. In the construction of Example 3, the lower layer material 2 is poured first, and the middle layer material 3, an ultra-high performance concrete, is poured 7d later. After pouring, the structure is kept moist and cured for 7d, and then the low-elasticity modulus soundproof ceramic tile adhesive 4 is used to paste the ceramic tile 5.

[0034] The weighted normalized impact sound pressure level and the impact sound pressure level improvement amount of the comparative examples and the examples are shown in Table 1.

[0035] Table 1. Weighted normalized impact sound pressure level and impact sound pressure level improvement amount of comparative examples and examples

[0036] As shown in Table 1, the three-layer sound insulation system of the present application can further improve the sound insulation performance. When the ceramic tile 5 is used as the decorative layer, the sound insulation amount can reach more than 15 dB, which can meet the requirements of the Residential Project Specification (GB 55038-2025) for the impact sound insulation of the partition floor. In Example 4, a lower elastic modulus material is used in the lower layer, which increases the difference in elastic modulus between different layers and achieves better sound insulation effect.

[0037] As described above, the present application can be well implemented. The above examples are only preferred embodiments of the present application and are not intended to limit the scope of the present application. Any equivalent changes and modifications made in accordance with the content of the present application are within the scope of the claims of the present application.

Claims

1. A three-layer sound insulation system for sound insulation of tile surface floor, arranged between concrete floor and tile surface, characterized in that: The method comprises a low elastic modulus lower layer material, a high elastic modulus middle layer material, and a low elastic modulus sound insulation ceramic tile adhesive which are sequentially arranged from bottom to top; The 28d elastic modulus of the low elastic modulus lower layer material is not greater than 2.0GPa, and the thickness is 10~25mm; the 28d elastic modulus of the high elastic modulus middle layer material is 10~45GPa, and the thickness is 10~25mm; the sum of the thicknesses of the low elastic modulus lower layer material and the high elastic modulus middle layer material is less than 40mm; the 28d elastic modulus of the low elastic modulus sound insulation ceramic tile adhesive is not greater than 3.5GPa, and the thickness is 3~10mm.

2. The three-layer sound insulation system according to claim 1, characterized in that: The low elastic modulus lower layer material is gypsum mortar with vitrified microspheres as aggregate, and its 28d absolute dry compressive strength is 2.5~12MPa; the high elastic modulus middle layer material is gypsum-based self-leveling mortar, and its 28d absolute dry compressive strength is not less than 20MPa; the low elastic modulus sound insulation ceramic tile adhesive uses vitrified microspheres as aggregate; or, the low elastic modulus lower layer material is gypsum mortar with vitrified microspheres as aggregate, and its 28d absolute dry compressive strength is 2.5~12MPa; the high elastic modulus middle layer material is ultra-high performance concrete, and its 28d compressive strength is not less than 100MPa; the low elastic modulus sound insulation ceramic tile adhesive uses vitrified microspheres as aggregate.

3. The three-layer sound insulation system according to claim 2, characterized in that: After the lower layer material with low elastic modulus is poured, the vitrified microspheres therein partially float upwards, and after hardening, a layer with more lightweight aggregate is formed on the upper part.

4. The three-layer sound insulation system according to claim 1, characterized in that: The low elastic modulus lower layer material is gypsum mortar with glass beads as aggregate, and flame-retardant polystyrene particles with a particle size of less than 3 mm are used to replace part of the glass beads, with a volume replacement of 10% to 70%.

5. The three-layer sound insulation system according to claim 4, characterized in that: After the low elastic modulus lower layer material is poured, the glass beads and flame-retardant polystyrene particles therein partially float up, and after hardening, a layer with more lightweight aggregate is formed on the upper part.

6. The three-layer sound insulation system according to claim 1 or 2, characterized in that: An interface agent is used between the low elastic modulus lower layer material and the floor slab.

7. The three-layer sound insulation system according to claim 1 or 2, characterized in that: The low elastic modulus sound insulation ceramic tile adhesive adopts vitrified microspheres as aggregates and is added with at least one of an air entraining agent and a plastic expansion agent to reduce the elastic modulus.

8. The three-layer sound insulation system according to claim 7, characterized in that: The low elastic modulus sound insulation ceramic tile adhesive contains the following materials in parts by mass: 30.0 to 50.0 parts of cementitious material, 5.0 to 10.0 parts of closed-cell vitrified microspheres, 0 to 0.3 parts of early strength agent, 0.1 to 0.4 parts of cellulose ether, 1.0 to 5.0 parts of dispersible rubber powder, 0.01 to 0.04 parts of air entraining agent, and 0.01 to 0.06 parts of plastic expansion agent.

9. The three-layer sound insulation system according to claim 8, characterized in that: The cementitious materials in low elastic modulus sound insulation ceramic tile adhesives include cement and mineral admixtures, of which the mass proportion of mineral admixtures is 10%~70%.

10. The three-layer sound insulation system according to claim 1 or 2, characterized in that: When the high elastic modulus middle layer material is gypsum-based self-leveling mortar, it should be naturally dried and cured for 14 days after pouring before the tiles are pasted with low elastic modulus sound insulation ceramic tile adhesive.

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