Gypsum board with noise reduction function
Through multi-layered structural design and material combination, gypsum board achieves efficient absorption of noise across the entire frequency band, solving the problems of incomplete high-frequency noise filtering and weak low-frequency noise processing in traditional gypsum board, thus improving noise treatment effect and board performance.
Patent Information
- Application Number
- CN202511546971.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-28
- Publication Date
- 2026-02-24
AI Technical Summary
Traditional gypsum board has a single, dense structure, which limits the energy loss of sound waves when they propagate inside. It is not thorough in filtering mid-to-high frequency noise and has a weak ability to handle low-frequency noise.
It adopts a multi-layer structure design, including a surface interception layer, a middle loose layer and a bottom support layer. Each layer has a density gradient design and an irregular perforated structure. It uses materials such as nanoparticles, hollow glass microspheres and basalt fibers to form a multi-layer noise reduction system. Through density gradient and pore design combined with an irregular perforated conical-stepped-spiral structure, it achieves noise absorption across the entire frequency band.
It achieves efficient absorption of noise across the entire frequency range of 20-4000Hz, with a sound absorption coefficient of 0.8-0.9, significantly improving the ability to handle low-frequency and mid-to-high-frequency noise, extending the service life of the board and improving its mechanical properties.
Smart Images
Figure CN121552750A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of gypsum board technology, and more particularly to a gypsum board with noise reduction function. Background Technology
[0002] In modern buildings, noise pollution has become a significant issue affecting the living and working experience. Noise generated by elevator operation, pipe vibration, personnel activity, and equipment operation can be transmitted into the interior space through walls, ceilings, and other structures. Gypsum board is widely used in building ceilings and wall decoration due to its advantages such as light weight, convenient construction, and low cost. However, traditional gypsum board is mostly a single, dense structure, with sound-absorbing additives simply mixed into the gypsum matrix. This results in limited energy loss during sound wave propagation within the gypsum matrix, leading to shortcomings such as incomplete filtering of mid-to-high frequency noise and weak low-frequency noise reduction capabilities. Summary of the Invention
[0003] This application provides a gypsum board with noise reduction function to solve the problems in the prior art where traditional gypsum boards are mostly single and dense structures, and the energy loss of sound waves is limited when they propagate inside, resulting in incomplete filtering of mid-to-high frequency noise and weak low-frequency noise processing capabilities.
[0004] This application provides a gypsum board with noise reduction function, comprising a surface retaining layer, a middle loose layer and a bottom support layer arranged sequentially. The density of the surface retaining layer is greater than the density of the bottom support layer, which is greater than the density of the middle loose layer. A sound insulation cavity is formed in the middle loose layer.
[0005] In one possible design, the surface retaining layer includes a surface gypsum substrate onto which a dense coating is sprayed. The dense coating is made of a mixture of silica aerogel and nano-calcium carbonate composite particles.
[0006] In one possible design, the gap between the nano-calcium carbonate composite particles is 10-20 nm.
[0007] In one possible design, the central porous layer comprises a middle gypsum matrix, hollow glass microspheres, and expanded perlite particles, with the hollow glass microspheres and expanded perlite particles dispersed in the middle gypsum matrix to form closed cavities.
[0008] In one possible design, a 50-500μm sound insulation cavity is formed between the intermediate gypsum matrix, hollow glass microspheres, and expanded perlite particles.
[0009] In one possible design, the bottom support layer comprises a base gypsum matrix and basalt fibers, with the basalt fibers interspersed within the gypsum matrix.
[0010] In one possible design, lignin fibers are also mixed into the underlying gypsum matrix.
[0011] In one possible design, the gap between the basalt fibers and lignin fibers is 0.2-1 mm.
[0012] In one possible design, irregular perforations are formed on the central loose layer. The irregular perforations include an inlet section, a contraction section, and an outlet section. The inlet section has a conical flared structure, the contraction section has a stepped variable diameter structure, the diameter of each step decreases sequentially, the step surface is perpendicular to the axis of the irregular perforation, and the outlet section has a spiral structure.
[0013] In one possible design, the inner wall of the irregular perforation has a roughened texture; and / or, the irregular perforation is filled with sound-absorbing material.
[0014] The beneficial effects of this application are as follows:
[0015] This application discloses a gypsum board with noise reduction function. Through the density gradient and pore design of the surface interception layer (10-20nm gap), the middle loose layer (50-500μm sound insulation cavity), and the bottom support layer (0.2-1mm fiber gap), combined with the cone-step-spiral structure with irregular perforations, it achieves efficient absorption of noise in the entire frequency band of 20-4000Hz. The sound absorption coefficient can reach 0.8-0.9, which is much higher than that of traditional gypsum board (0.1-0.2).
[0016] Nanoparticles in the surface trapping layer are bonded to the gypsum matrix via chemical bonds, while basalt fibers in the bottom support layer enhance mechanical properties, and lignin fibers regulate humidity to prevent mold growth, effectively extending the lifespan of the board. Meanwhile, the sound-absorbing material filling the irregularly shaped perforations and the roughened inner wall design prevent material detachment and direct sound wave penetration. Attached Figure Description
[0017] To more clearly illustrate the technical solutions in the specific embodiments of this application or the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.
[0018] Figure 1 This is a structural schematic diagram of a gypsum board with noise reduction function provided in an embodiment of this application;
[0019] Figure 2 This is a schematic diagram of an irregularly shaped perforated gypsum board with noise reduction function, provided as an embodiment of this application.
[0020] Figure label:
[0021] 1. Surface retaining layer; 2. Middle loose layer; 3. Bottom support layer; 4. Irregular perforation; 41. Inlet section; 42. Contraction section; 43. Outlet section. Detailed Implementation
[0022] The technical solutions of this application will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.
[0023] The following is combined with Figures 1-2 This application describes a gypsum board with noise reduction function provided in an embodiment of the present application.
[0024] Reference Figure 1 As shown, the gypsum board provided in this application embodiment includes a surface interception layer 1, a middle loose layer 2 and a bottom support layer 3 arranged sequentially. The density of the surface interception layer 1 is greater than the density of the bottom support layer 3, which is greater than the density of the middle loose layer 2. A sound insulation cavity is formed in the middle loose layer 2. Through density distribution and sound insulation cavity design, a multi-layer noise reduction system of interception-resonance-support is constructed.
[0025] The surface interception layer 1 serves as the first barrier for noise filtering, primarily used to absorb mid-to-high frequency sound waves (1000-4000Hz). It comprises a surface gypsum substrate, onto which a dense coating is sprayed. This dense coating is composed of a mixture of silica aerogel and nano-calcium carbonate composite particles, wherein the gap between the nano-calcium carbonate composite particles is controlled at 10-20nm, which precisely matches the wavelength of mid-to-high frequency sound waves.
[0026] Nanoscale composite particles are applied to a gypsum substrate using a directional spraying process to form a uniform and dense layer. After modification with a silane coupling agent, the particle surface can form stable chemical bonds with calcium ions in the gypsum substrate, preventing particle shedding during long-term use. Simultaneously, the 10-20nm particle gaps create a "trapping-friction" effect on mid-to-high frequency sound waves. Sound waves repeatedly reflect within the gaps and rub against the pore walls, converting sound energy into heat energy for dissipation, thus achieving preliminary filtering of mid-to-high frequency noise.
[0027] The middle loose layer 2 is the noise reduction core layer, mainly used to absorb low-frequency sound waves (20-500Hz). It includes a middle gypsum matrix, hollow glass microspheres and expanded perlite particles. The hollow glass microspheres (particle size 5-20μm) and expanded perlite particles (particle size 100-300μm) are dispersed in the middle gypsum matrix through a suspension casting process, forming a 50-500μm sound insulation cavity between the middle gypsum matrix and the two types of particles.
[0028] When sound waves, initially filtered by the surface interception layer 1, enter the middle loose layer 2, low-frequency sound waves resonate within the sound insulation cavity. During this resonance, the sound wave energy is repeatedly absorbed by the cavity wall (composed of the middle gypsum matrix, the hollow glass microsphere shell, and the surface of expanded perlite particles). This effectively improves energy loss rate by over 40%, particularly addressing low-frequency noises such as elevator operation and pipe vibrations that are difficult to handle with traditional gypsum boards. Furthermore, the hollow structure of the hollow glass microspheres reduces the overall density of the middle loose layer 2, improving noise reduction performance while reducing the board's weight and facilitating installation.
[0029] The bottom support layer 3 has both support and auxiliary noise reduction functions. It includes a bottom gypsum matrix, basalt fibers and lignin fibers. Basalt fibers (5-10 mm in length and 10-20 μm in diameter) and lignin fibers (2-5 mm in length and 5-10 μm in diameter) are interspersed in the bottom gypsum matrix, and a gap of 0.2-1 mm is formed between the two types of fibers.
[0030] The high strength of basalt fiber enhances the mechanical properties of the underlying gypsum matrix, preventing a decrease in the overall strength of the board due to the porous structure of the surface retaining layer 1 and the central loose layer 2. Lignin fiber has excellent moisture absorption properties, regulating the internal humidity of the board and preventing mold growth due to dampness. Simultaneously, the 0.2-1mm fiber gaps further capture residual high-frequency sound wave wakes, forming a final noise reduction barrier that works in conjunction with the surface retaining layer 1 and the central loose layer 2 to achieve full-frequency noise absorption.
[0031] Reference Figure 2 As shown, in order to further extend the sound wave propagation path and increase sound energy loss, an irregular perforation 4 is formed on the middle loose layer 2. The irregular perforation 4 penetrates the middle loose layer 2 and includes an inlet section 41, a contraction section 42 and an outlet section 43.
[0032] Specifically, the inlet section 41 has a tapered flared structure with an inlet diameter of 8-10 mm and an outlet diameter (at the connection point with the constriction section 42) of 4-5 mm. The tapered angle is 30°-45°, which can collect sound, focusing dispersed sound waves into the perforation. At the same time, the sound waves are reflected for the first time through the tapered hole wall, reducing the sound energy that directly enters the perforation. Furthermore, the large-diameter inlet facilitates the filling of sound-absorbing materials such as glass wool.
[0033] The contraction section 42 has a stepped diameter-changing structure, with a length of 15-20mm and 2-3 steps. The diameter of each step decreases by 0.5-1mm. The step surface is perpendicular to the axis of the irregular perforation 4. After the sound wave enters, it will undergo secondary reflection on the step surface. The reflected sound wave interferes with the incident sound wave to form a standing wave effect, which reduces the sound wave propagation speed and prolongs the propagation time, improving the loss rate of mid-frequency sound waves (500-1000Hz) by more than 35%. At the same time, the inner wall of the perforation is roughened (surface roughness Ra = 5-10μm) to increase the friction area between the sound wave and the hole wall.
[0034] The outlet section 43 has a spiral structure with a length of 20-25mm and a constant diameter. The hole wall has spiral protrusions (pitch 5-8mm, protrusion height 0.5-1mm), which can guide the sound waves to propagate along the spiral path, increasing the propagation path by 50%-80% compared to a straight hole, further aggravating the sound energy loss. In addition, the spiral structure can disrupt the directionality of sound wave propagation and prevent sound waves from directly penetrating the plate.
[0035] Through the density gradient and pore design of the surface retaining layer 1 (10-20nm gap), the middle loose layer 2 (50-500μm sound insulation cavity), and the bottom support layer 3 (0.2-1mm fiber gap), combined with the conical-stepped-spiral structure of the irregular perforated layer 4, it achieves efficient absorption of noise in the entire frequency band of 20-4000Hz, with a sound absorption coefficient of 0.8-0.9, which is far higher than that of traditional gypsum board.
[0036] The preparation steps of the gypsum board in this application are as follows:
[0037] Preparation of bottom support layer 3: Gypsum powder and water are mixed and stirred at a mass ratio of 1:0.6 to form gypsum slurry. 5% of basalt fiber (5-10 mm in length and 10-20 μm in diameter) and 3% of lignin fiber (2-5 mm in length and 5-10 μm in diameter) are added by mass of gypsum powder. After stirring evenly, the mixture is poured into a mold, vibrated and compacted, and cured at 25℃ and 60% relative humidity for 24 hours to form a bottom support layer 3 with a thickness of 8-12 mm.
[0038] Preparation of the middle loose layer 2: Gypsum powder and water are mixed at a mass ratio of 1:0.7 to form a gypsum slurry. Hollow glass microspheres (particle size 5-20μm) accounting for 8% of the mass of gypsum powder and expanded perlite particles (particle size 100-300μm) accounting for 6% of the mass of gypsum powder are added. The mixture is evenly covered on the surface of the bottom support layer 3 using a suspension casting process, with a thickness controlled at 6-8mm. It is cured for 24h at 25℃ and 60% relative humidity to form the middle loose layer 2 (with the sound insulation cavity size of 50-500μm).
[0039] Preparation of surface retaining layer 1: Silica aerogel and nano-calcium carbonate are mixed at a mass ratio of 1:2. Silane coupling agent (2% of the mixed powder mass) and water (30% of the mixed powder mass) are added to prepare a spraying slurry. The slurry is uniformly sprayed onto the surface of the loose middle layer 2 using a high-pressure airless spraying device. The spraying thickness is 0.5-2 mm. The slurry is dried for 12 hours at 30℃ and 50% relative humidity to form surface retaining layer 1 (with nanoparticle gaps of 10-20 nm).
[0040] Processing of irregular perforations 4: Using CNC drilling equipment, irregular perforations 4 are processed on the middle loose layer 2 and the surface interception layer 1. The inlet section 41 (conical flare, diameter 8-10mm to 4-5mm, angle 30°-45°), the contraction section 42 (stepped diameter change, 2-3 steps, diameter decreases by 0.5-1mm in succession), and the outlet section 43 (spiral structure, diameter unchanged, pitch 5-8mm). After the perforation is completed, the inner wall is roughened (Ra=5-10μm), and glass wool is filled into the perforation.
[0041] Performance testing of gypsum board in this application:
[0042] The performance of the prepared gypsum board (1200mm×2400mm×18-22mm) was tested, and the results are as follows:
[0043] Sound absorption performance: The sound absorption coefficient is 0.82-0.88 in the 20-4000Hz frequency range, with a sound absorption coefficient of 0.75-0.80 in the low-frequency range of 20-500Hz and a sound absorption coefficient of 0.85-0.88 in the mid-high frequency range of 1000-4000Hz.
[0044] Mechanical properties: Bending failure load ≥1200N, elongation at break ≤0.3%, no obvious deformation or cracking.
[0045] Stability: After being tested in an environment with a temperature cycle of -10℃ to 50℃ (50 cycles) and a relative humidity of 90% (72 hours), the board showed no mold growth or delamination, and the sound absorption coefficient change rate was ≤5%.
[0046] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, 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 application.
[0047] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.
[0048] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between components; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.
[0049] In this application, the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.
[0050] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.
Claims
1. A gypsum board with noise reduction function, characterized in that, It includes a surface retaining layer, a middle loose layer and a bottom support layer arranged in sequence. The density of the surface retaining layer is greater than the density of the bottom support layer, which is greater than the density of the middle loose layer. A sound insulation cavity is formed in the middle loose layer.
2. The gypsum board with noise reduction function according to claim 1, characterized in that, The surface retention layer includes a surface gypsum substrate, on which a dense coating is sprayed. The dense coating is made of a mixture of silica aerogel and nano-calcium carbonate composite particles.
3. A gypsum board with noise reduction function according to claim 2, characterized in that, The gaps between the nano-calcium carbonate composite particles are 10-20 nm.
4. A gypsum board with noise reduction function according to claim 1, characterized in that, The central porous layer comprises a middle gypsum matrix, hollow glass microspheres, and expanded perlite particles. The hollow glass microspheres and the expanded perlite particles are dispersed in the middle gypsum matrix to form a closed cavity.
5. A gypsum board with noise reduction function according to claim 4, characterized in that, A sound insulation cavity of 50-500μm is formed between the intermediate gypsum matrix, the hollow glass microspheres, and the expanded perlite particles.
6. A gypsum board with noise reduction function according to claim 1, characterized in that, The bottom support layer includes a bottom gypsum matrix and basalt fibers, with the basalt fibers interspersed in the gypsum matrix.
7. A gypsum board with noise reduction function according to claim 6, characterized in that, The underlying gypsum matrix also contains lignin fibers.
8. A gypsum board with noise reduction function according to claim 7, characterized in that, The gap between the basalt fiber and the lignin fiber is 0.2-1 mm.
9. A gypsum board with noise reduction function according to any one of claims 1-8, characterized in that, The loose middle layer has irregularly shaped perforations, which include an inlet section, a contraction section, and an outlet section. The inlet section has a tapered flared structure, the contraction section has a stepped variable diameter structure, with the diameter of each step decreasing sequentially, and the stepped surface is perpendicular to the axial direction of the irregularly shaped perforation. The outlet section has a spiral structure.
10. A gypsum board with noise reduction function according to claim 9, characterized in that, The inner wall of the irregular perforation has a roughened texture; and / or, the irregular perforation is filled with sound-absorbing material.