Preparation method of sound insulation aluminum honeycomb floor

Abstract

The invention belongs to the technical field of floors, and particularly relates to a sound insulation aluminum honeycomb floor preparation method which comprises the steps that S1, panels are pretreated, specifically, an upper layer panel and a lower layer panel are prepared, and the bonding surfaces of the upper layer panel and the lower layer panel are cleaned, polished and sprayed with a primer; s2, pretreatment of the aluminum honeycomb core: placing the aluminum honeycomb core in a vacuum environment, filling porous sound-absorbing materials into pores of the aluminum honeycomb core, and performing pre-pressing and shaping; s3, assembling and primary hot pressing are carried out, specifically, the pretreated lower-layer panel, the filled aluminum honeycomb core and the upper-layer panel are assembled in sequence, an adhesive is coated on a bonding interface, and then the assembled panel is fed into a hot press to be subjected to hot pressing curing under certain pressure and temperature; and S4, curing and cooling are conducted, specifically, constant-temperature and constant-humidity curing is conducted on the hot-pressed board, and the device solves the problem that when the sound insulation aluminum honeycomb floor is prepared at present, the hot-pressing pressure on the board cannot be accurately controlled, so that the board is damaged or the hot-pressing quality is reduced.

Description

Technical Field

[0001] This invention belongs to the technical field of flooring, specifically relating to a method for preparing sound-insulating aluminum honeycomb flooring. Background Technology

[0002] Traditional flooring materials, such as solid wood flooring, engineered wood flooring, and stone flooring, generally suffer from poor sound insulation, especially against impact sounds (such as footsteps and falling objects). This can easily cause noise pollution in multi-story residential buildings, office buildings, hospitals, and other similar locations, affecting the quality of life and working environment. While this can be improved by adding an extra sound insulation layer, this increases the complexity and cost of installation.

[0003] Aluminum honeycomb core, as a lightweight and high-strength material, has been widely used in aerospace, rail transportation, and other fields. Its honeycomb structure effectively absorbs and disperses energy and sound waves. In recent years, some have attempted to apply aluminum honeycomb structures to flooring, aiming to achieve lightweight, high-strength, and sound-insulating effects. However, existing aluminum honeycomb flooring has some limitations. The bonding strength between the aluminum honeycomb core and the upper and lower panels is insufficient, and delamination may occur after long-term use. Therefore, hot-pressing curing is required during the production process. However, current conventional hot-pressing methods use hydraulic control, which is energy-intensive and lacks pressure precision control, leading to easy breakage of the panels or insufficient hot-pressing strength, affecting production quality. This phenomenon has become a problem that urgently needs to be solved by researchers in this field. Summary of the Invention

[0004] The purpose of this invention is to provide a method for preparing sound-insulating aluminum honeycomb flooring to solve the problems mentioned in the background art.

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a method for preparing sound-insulating aluminum honeycomb flooring, the method comprising: step S1, panel pretreatment, preparing upper and lower panels, and cleaning, polishing and spraying primer on their bonding surfaces; step S2, aluminum honeycomb core pretreatment, placing the aluminum honeycomb core in a vacuum environment, filling its pores with porous sound-absorbing material, and pre-pressing and shaping; step S3, assembly and one-time hot pressing, assembling the pretreated lower panel, the filled aluminum honeycomb core, and the upper panel in sequence. After applying adhesive to the bonding interface, the board is placed in a hot press and cured under certain pressure and temperature. Step S4, Curing and Cooling: The hot-pressed board is cured at a constant temperature and humidity, and then cooled naturally. Step S5, Curing and Edge Treatment: The board is cut into flooring units, the sides are processed to form a connecting structure, and the exposed honeycomb core sides are sealed. Step S6, Surface Treatment and Post-Processing: The flooring surface and connecting structure are given final treatment and inspection. Step S7, Inspection and Packaging: The finished flooring is tested for performance and packaged after passing the test.

[0006] The present invention further explains that in step S2, the porous sound-absorbing material is a soft porous elastic material made by mixing centrifugal glass wool, rock wool, or rubber particles with an environmentally friendly adhesive.

[0007] The present invention further explains that, in step S3, the adhesive is epoxy resin structural adhesive or polyurethane adhesive, and the hot pressing process adopts a segmented pressurization method, first applying low pressure for 1-3 minutes, and then increasing to the target pressure for pressure holding and curing; the upper panel is anodized aluminum plate or aluminum plate with a wear-resistant coating, the lower panel is aluminum plate or galvanized steel plate, and the aluminum honeycomb core is a hexagonal aluminum foil honeycomb core; in step S5, the sealing treatment is to fill and seal the sides with silicone sealant or polyurethane sealant.

[0008] The present invention further illustrates that the hot press in step S3 includes an output motor, an output shaft, a screw, a sleeve, a hot press shaft, and a hot press plate; the output shaft is fixedly connected to the output end of the output motor, the upper end and the lower end of the screw are respectively connected to the lower end of the output shaft and the inside of the sleeve, the bottom of the sleeve is provided with a countersunk hole, and the hot press shaft is slidably connected in the countersunk hole, the hot press plate is fixedly installed on the lower end of the hot press shaft, and the output motor is connected to an external lifting mechanism; inclined blocks are provided on both the front and rear sides of the hot press shaft, and inclined grooves are provided on the surface of the inclined blocks, and a push rod is fixed to the inner wall of the sleeve, the inner end of the push rod is embedded in the inclined groove.

[0009] The present invention further illustrates that the inner end of the top rod is spherical, and the two ends of the inclined groove are arc-shaped; the two inclined blocks are arranged opposite each other and inclined upward.

[0010] The present invention further describes that an undulating plate is provided above the hot pressing shaft, and U-shaped grooves are provided on both the left and right sides of the undulating plate. A connecting rod is provided inside the U-shaped groove, and the lower end of the connecting rod is welded and fixed to one end of the inclined block. A through hole is provided in the middle of the hot pressing shaft, and a rotating shaft is rotatably connected in the through hole. The front and rear ends of the rotating shaft are respectively connected to two inclined blocks by bearings, and the inner sides of the two inclined blocks are in contact with the outer surface of the hot pressing shaft.

[0011] The present invention further illustrates that threaded holes are provided at the lower end of the output shaft and the upper part of the sleeve, and the upper and lower ends of the screw are respectively threaded into the threaded holes of the output shaft and the sleeve; the lower end of the screw is connected to the upper surface of the undulating plate by a bearing.

[0012] The present invention further illustrates that the upper end of the connecting rod is spherical, and the length of the U-shaped groove is greater than the outer diameter of the connecting rod, that is, the connecting rod is movably connected in the U-shaped groove.

[0013] The present invention further illustrates that a nut is fixed to the outside of the screw, and the output motor is connected to an external control system. The external control system is used by the operator to control the rotation angle of the output motor, thereby adjusting the pressure of the hot press.

[0014] Compared with the prior art, the beneficial effects achieved by the present invention are as follows: By filling the aluminum honeycomb core with porous sound-absorbing material, the present invention effectively blocks and absorbs the sound energy transmitted by airborne sound waves and structural vibrations, and in particular significantly reduces the impact sound pressure level, solving the problem of sound transmission in the traditional hollow aluminum honeycomb core structure. Through strict panel pretreatment, the application of high-performance structural adhesive and optimized hot-press curing process, extremely high bonding strength and durability between the panel and the honeycomb core are ensured, making the floor strong in load-bearing capacity, impact-resistant and not easily deformed. The method has clear steps and clear process parameters, making it suitable for large-scale industrial production, and the product quality is stable and reliable. Compared to hydraulic hot pressing, the electric motor-driven hot pressing method is more energy-efficient and offers higher pressure control precision. This prevents excessive pressure from damaging the sheet material or insufficient pressure from weakening the connection between panels, thus improving the hot pressing quality. Furthermore, the overall structure is simple, the manufacturing cost is low, and it is suitable for sheet materials requiring different pressures, making it widely applicable. During the low-pressure-minute process, the push rod moves to the middle of the inclined groove. When the target pressure is reached for pressure holding and curing, the push rod moves to the top of the inclined groove, ensuring high pressure application precision and protecting the sheet material. When the pressure required for the board is high during pressure holding and curing, the hot pressing pressure increases after the push rod slides to the top in the inclined groove, thus increasing the pressure holding and curing pressure. This adjustment is convenient and quick, and it is suitable for the pressure holding and curing pressure required for different boards, further expanding its application range. When the pressure required for the board is low during pressure holding and curing, the hot pressing pressure decreases after the push rod slides to the top in the inclined groove, thus reducing the pressure for protective curing. This provides sufficient protection for boards with low compressive strength, preventing breakage and affecting production quality. Attached Figure Description

[0015] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the preparation method of the present invention; Figure 2 This is a schematic diagram of the hot press of the present invention; Figure 3 This is a plan view of the hot press of the present invention; Figure 4 This is a schematic diagram of the internal structure of the sleeve of the present invention; Figure 5This is an exploded view of the present invention; Figure 6 This is a schematic diagram showing the cooperation between the inclined block, connecting rod, and undulating plate of the present invention. In the diagram: 1. Output shaft; 2. Screw; 21. Nut; 3. Sleeve; 31. Push rod; 4. Hot press shaft; 41. Inclined block; 411. Inclined groove; 42. Ripple plate; 421. U-shaped groove; 43. Connecting rod; 44. Rotating shaft; 5. Hot press plate. Detailed Implementation

[0016] The following detailed, non-limiting description of the technical solution of the present invention, in conjunction with preferred embodiments and accompanying drawings, is provided. Obviously, the described embodiments are merely some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0017] Please see Figures 1-6 The present invention provides a technical solution: a method for preparing sound-insulating aluminum honeycomb flooring, the preparation method comprising: Step S1: Panel pretreatment. Prepare the upper and lower panels, and clean, sand and spray primer on their bonding surfaces. Step S2: Pre-treatment of aluminum honeycomb core. Place the aluminum honeycomb core in a vacuum environment, fill its pores with porous sound-absorbing material, and pre-press and shape it. Step S3, Assembly and First Hot Press: The pre-treated lower panel, the filled aluminum honeycomb core, and the upper panel are assembled in sequence. After applying adhesive to the bonding interface, they are sent into a hot press for hot pressing and curing under certain pressure and temperature. Step S4, Curing and Cooling: The hot-pressed board is cured at a constant temperature and humidity, and then cooled naturally. Step S5, Curing and Edge Treatment: Cut the board into floor units, process the sides to form a connecting structure, and seal the exposed honeycomb core sides. Step S6, Surface treatment and post-processing: Perform final treatment and inspection on the floor surface and connection structure; Step S7: Inspection and Packaging. The finished flooring is inspected for performance and packaged after passing the inspection.

[0018] In step S2, the porous sound-absorbing material is a soft porous elastic material made by mixing centrifugal glass wool, rock wool, or rubber particles with an environmentally friendly adhesive.

[0019] In step S3, the adhesive is epoxy resin structural adhesive or polyurethane adhesive. The hot pressing process adopts a segmented pressure method, first applying low pressure for 1-3 minutes, and then increasing to the target pressure for pressure holding and curing. The upper panel is anodized aluminum plate or aluminum plate with a wear-resistant coating, the lower panel is aluminum plate or galvanized steel plate, and the aluminum honeycomb core is an aluminum foil honeycomb core with hexagonal cells. In step S5, the sealing process involves filling and sealing the sides with silicone sealant or polyurethane sealant. By filling the aluminum honeycomb core with porous sound-absorbing material, the sound energy transmitted by airborne sound waves and structural vibrations is effectively blocked and absorbed, especially significantly reducing the impact sound pressure level. This solves the sound transmission problem of traditional hollow aluminum honeycomb core structures. Through strict panel pretreatment, the application of high-performance structural adhesives, and optimized hot-press curing processes, extremely high bonding strength and durability between the panel and the honeycomb core are ensured, making the flooring strong in load-bearing capacity, impact-resistant, and not easily deformed. Its core material is aluminum, maintaining the lightweight characteristics of the aluminum honeycomb structure, facilitating transportation and installation, and reducing building load. The aluminum material and surface treatment give the flooring good fire resistance, moisture resistance, corrosion resistance, and wear resistance. Sealed edge treatment further enhances moisture resistance and durability. The method has clear steps and well-defined process parameters, making it suitable for large-scale industrial production, and the product quality is stable and reliable.

[0020] The hot press in step S3 includes an output motor, an output shaft 1, a screw 2, a sleeve 3, a hot press shaft 4, and a hot press plate 5; The output shaft 1 is fixedly connected to the output end of the output motor. The upper and lower ends of the screw 2 are respectively connected to the lower end of the output shaft 1 and the inside of the sleeve 3. The bottom of the sleeve 3 is provided with a countersunk hole, and the hot pressing shaft 4 is slidably connected in the countersunk hole. The hot pressing plate 5 is fixedly installed at the lower end of the hot pressing shaft 4. The output motor is connected to the external elevator. Inclined blocks 41 are provided on both the front and rear sides of the hot pressing shaft 4, and inclined grooves 411 are provided on the surface of the inclined blocks 41. A push rod 31 is fixed on the inner wall of the sleeve 3, and the inner end of the push rod 31 is embedded in the inclined groove 411.

[0021] The inner end of the push rod 31 is spherical, and the two ends of the inclined groove 411 are arc-shaped; The two tilting blocks 41 are positioned opposite each other and tilted upwards; During hot pressing, the external lifting platform drives the output motor to move downwards. The output motor drives the hot pressing plate 5 downwards through the output shaft 1, screw 2, sleeve 3, and hot pressing shaft 4 until it contacts the surface of the board. Then, the output motor runs, driving the output shaft 1 to rotate. The output shaft 1 drives the sleeve 3 to rotate through the screw 2. When the sleeve 3 rotates, it drives the top rod 31 on its inner wall to rotate around the center. The top rod 31 slides in the inclined groove 411 on the inclined block 41. During the sliding process, it presses down the hot pressing shaft 4, thereby driving the hot pressing plate 5 to press down and hot press the surface of the board. Compared with hot pressing by hydraulic means, motor drive is more energy-efficient and has higher pressure control precision. It can avoid excessive pressure causing board damage or insufficient pressure causing low connection strength between panels, thereby improving the quality of hot pressing. Moreover, the overall structure is simple, the manufacturing cost is low, and it can be applied to plates that require different pressures, making it widely applicable. During the low-pressure 1-3 minute process, the push rod 31 moves to the middle part of the inclined groove 411. When the target pressure is raised for pressure holding and curing, the push rod 31 moves to the uppermost part of the inclined groove 411. The pressure application is highly accurate and plays a role in protecting the board.

[0022] A convex plate 42 is provided above the hot pressing shaft 4. U-shaped grooves 421 are provided on both the left and right sides of the convex plate 42. A connecting rod 43 is provided inside the U-shaped groove 421. The lower end of the connecting rod 43 is welded and fixed to one end of the inclined block 41. The hot pressing shaft 4 has a through hole in the middle, and a rotating shaft 44 is rotatably connected in the through hole. The front and rear ends of the rotating shaft 44 are respectively connected to two inclined blocks 41 by bearings, and the inner sides of the two inclined blocks 41 are in contact with the outer surface of the hot pressing shaft 4.

[0023] The lower end of the output shaft 1 and the upper part of the sleeve 3 are provided with threaded holes, and the upper and lower ends of the screw 2 are respectively threaded into the threaded holes of the output shaft 1 and the sleeve 3. The lower end of the screw 2 is connected to the upper surface of the undulating plate 42 by a bearing; Example 1: When the pressure required for the board material during pressure holding and curing is high, the sleeve 3 is fixed and the screw 2 is rotated. After the screw 2 rotates, the upper part moves upward along the threaded hole of the output shaft 1, and the lower part moves upward along the threaded hole of the sleeve 3. At the same time, the lower end of the screw 2 moves upward, driving the undulating plate 42 to move upward. The undulating plate 42 drives the connecting rod 43 to move upward. The connecting rod 43 drives the upper end of the inclined block 41 to move upward. At the same time, the inclined block 41 rotates through the rotating shaft 44. After the inclined block 41 moves upward, the top rod 31 slides to the top in the inclined groove 411, and the hot pressing pressure increases, which increases the pressure holding and curing pressure. The adjustment is convenient and quick, and it is suitable for the pressure holding and curing pressure required for different boards, further expanding the application range. Example 2: When the pressure required for the board is small during pressure holding and curing, the screw 2 is rotated in the opposite direction. After the top rod 31 slides to the top in the inclined groove 411, the hot pressing pressure is reduced, which reduces the pressure for protection and curing. This provides sufficient protection for boards with low compressive strength, preventing breakage and affecting production quality. The pressure adjustment during pressure holding and curing is highly precise. Only the number of rotations of screw 2 needs to be controlled. When screw 2 is rotated, only the position of screw 2 changes, while the position and height of sleeve 3 and hot press plate 5 remain unchanged. This avoids driving the external elevator again, reducing energy consumption. At the same time, it can ensure the distance between hot press plate 5 and the plate, avoiding affecting the pressure value changes during hot pressing and ensuring the accuracy of hot pressing pressure.

[0024] The upper end of the connecting rod 43 is spherical, and the length of the U-shaped groove 421 is greater than the outer diameter of the connecting rod 43, that is, the connecting rod 43 is movably connected in the U-shaped groove 421; When the connecting rod 43 moves, it moves left and right within the U-shaped groove 421 and is limited by the spherical part at its upper end so that the tilting block 41 can rotate smoothly.

[0025] A nut 21 is fixed to the outside of the screw 2. The output motor is connected to an external control system. The external control system is used by the operator to control the rotation angle of the output motor, thereby adjusting the pressure of the hot press. When rotating screw 2, a wrench is used in conjunction with nut 21 to make rotating screw 2 more convenient. By setting an external control system, the pressure of hot pressing can be precisely controlled. When the pressure needs to be reduced during pressure holding and curing, and when screw 2 does not need to be adjusted, the rotation angle of the output motor can be changed by driving the external control system. The operation is more convenient and the hot press can achieve better results.

[0026] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0027] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features, and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for preparing sound-insulating aluminum honeycomb flooring, characterized in that: The preparation method includes: Step S1: Panel pretreatment. Prepare the upper and lower panels, and clean, sand and spray primer on their bonding surfaces. Step S2: Pre-treatment of aluminum honeycomb core. Place the aluminum honeycomb core in a vacuum environment, fill its pores with porous sound-absorbing material, and pre-press and shape it. Step S3, Assembly and First Hot Press: The pre-treated lower panel, the filled aluminum honeycomb core, and the upper panel are assembled in sequence. After applying adhesive to the bonding interface, they are sent into a hot press for hot pressing and curing under certain pressure and temperature. Step S4, Curing and Cooling: The hot-pressed board is cured at a constant temperature and humidity, and then cooled naturally. Step S5, Curing and Edge Treatment: Cut the board into floor units, process the sides to form a connecting structure, and seal the exposed honeycomb core sides. Step S6, Surface treatment and post-processing: Perform final treatment and inspection on the floor surface and connection structure; Step S7: Inspection and Packaging. The finished flooring is inspected for performance and packaged after passing the inspection.

2. The method for preparing a sound-insulating aluminum honeycomb floor according to claim 1, characterized in that: In step S2, the porous sound-absorbing material is a soft porous elastic material made by mixing centrifugal glass wool, rock wool, or rubber particles with an environmentally friendly adhesive.

3. The method for preparing a sound-insulating aluminum honeycomb floor according to claim 2, characterized in that: In step S3, the adhesive is epoxy resin structural adhesive or polyurethane adhesive. The hot pressing process adopts a segmented pressurization method, first applying low pressure for 1-3 minutes, and then increasing to the target pressure for pressure holding and curing. The upper panel is an anodized aluminum plate or an aluminum plate with a wear-resistant coating, the lower panel is an aluminum plate or a galvanized steel plate, and the aluminum honeycomb core is an aluminum foil honeycomb core with hexagonal cells. In step S5, the sealing process involves filling and sealing the sides with silicone sealant or polyurethane sealant.

4. The method for preparing a sound-insulating aluminum honeycomb floor according to claim 3, characterized in that: The hot press in step S3 includes an output motor, an output shaft (1), a screw (2), a sleeve (3), a hot press shaft (4), and a hot press plate (5). The output shaft (1) is fixedly connected to the output end of the output motor. The upper end and lower end of the screw (2) are respectively connected to the lower end of the output shaft (1) and the inside of the sleeve (3). The bottom of the sleeve (3) is provided with a countersunk hole, and the hot pressing shaft (4) is slidably connected in the countersunk hole. The hot pressing plate (5) is fixedly installed at the lower end of the hot pressing shaft (4). The output motor is connected to the external elevator. Inclined blocks (41) are provided on both the front and rear sides of the hot pressing shaft (4), and inclined grooves (411) are provided on the surface of the inclined blocks (41). A push rod (31) is fixed on the inner wall of the sleeve (3), and the inner end of the push rod (31) is embedded in the inclined groove (411).

5. The method for preparing a sound-insulating aluminum honeycomb floor according to claim 4, characterized in that: The inner end of the top rod (31) is spherical, and the two ends of the inclined groove (411) are arc-shaped; The two inclined blocks (41) are positioned opposite each other and tilted upwards.

6. The method for preparing a sound-insulating aluminum honeycomb floor according to claim 5, characterized in that: An undulating plate (42) is provided above the hot pressing shaft (4). U-shaped grooves (421) are provided on both the left and right sides of the undulating plate (42). A connecting rod (43) is provided inside the U-shaped groove (421). The lower end of the connecting rod (43) is welded to one end of the inclined block (41). The hot pressing shaft (4) has a through hole in the middle, and a rotating shaft (44) is rotatably connected in the through hole. The front and rear ends of the rotating shaft (44) are respectively connected to two inclined blocks (41) by bearings, and the inner side of the two inclined blocks (41) is in contact with the outer surface of the hot pressing shaft (4).

7. The method for preparing a sound-insulating aluminum honeycomb floor according to claim 6, characterized in that: The lower end of the output shaft (1) and the upper part of the sleeve (3) are provided with threaded holes, and the upper end and lower end of the screw (2) are respectively threaded into the threaded holes of the output shaft (1) and the sleeve (3). The lower end of the screw (2) is connected to the upper surface of the undulating plate (42) by a bearing.

8. The method for preparing a sound-insulating aluminum honeycomb floor according to claim 7, characterized in that: The upper end of the connecting rod (43) is spherical, and the length of the U-shaped groove (421) is greater than the outer diameter of the connecting rod (43), that is, the connecting rod (43) is movably connected in the U-shaped groove (421).

9. A method for preparing a sound-insulating aluminum honeycomb floor according to claim 8, characterized in that: A nut (21) is fixed to the outside of the screw (2). The output motor is connected to an external control system. The external control system is used by the operator to control the rotation angle of the output motor, thereby adjusting the pressure of the hot press.

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