Sound insulation and heat insulation composite functional layer for building and preparation process thereof

Abstract

The invention discloses a sound-insulation and heat-insulation composite functional layer for buildings and a preparation process of the sound-insulation and heat-insulation composite functional layer. The composite functional layer 400 is composed of a foam metal plate 100 with a hole type gradient, the hole opening surface of the composite functional layer 400 is processed to form a rough surface 401, and the composite functional layer 400 is provided with a through connecting key 403 and a peripheral connecting structure 402. According to the invention, through the collaborative design of'rough surface-connecting key-connecting structure ', the application bottleneck that high-performance foam metal cannot be adhered and mounted in a building is systematically solved, transition from a material to a reliable functional layer is realized, and the method is particularly suitable for new construction and transformation of building concrete members.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of green building energy saving and structural material, and particularly relates to a structural and functional integrated composite functional layer based on a hole type gradient foam metal and having excellent sound insulation and heat insulation performance and concrete combination performance and a preparation process thereof. BACKGROUND

[0002] With the improvement of green building and energy saving and emission reduction requirements, the development of an integrated enclosure component having structural bearing and heat and sound insulation functions has become an important research direction. Traditional building heat and sound insulation systems (such as externally attached polyurethane foam and rock wool board) are usually constructed separately from the structural layer, and have problems such as weak interface combination, easy delamination, complex process, poor durability and the like.

[0003] Foam metal, especially gradient foam metal, provides a new idea for solving the above problems. However, existing gradient foam metal technology is mostly focused on the gradient control of macroscopic density or composition, and the product is still used as a "base material". Even if an advanced foam metal material having a "open hole surface-internal closed hole" hole type gradient is obtained, it still faces two major industrialization bottlenecks in building applications: Insufficient interface combination performance: although the open hole surface is better than the closed hole surface, the interface without targeted design still cannot meet the requirements of the adhesion strength, air tightness and anti-peeling performance of the concrete; Insufficient system assembly performance: lacking reliable mechanical anchoring measures with the main structure of the building, and standardized interfaces for efficient splicing between blocks, which cannot be quickly constructed and assembled as reliable "functional units".

[0004] Therefore, there is an urgent need in the art for an innovative solution to systematically solve the application pain points of "not being able to be assembled" (system assembly) and "not being able to be adhered" (interface combination). SUMMARY

[0005] (I) Technical problems to be solved The present application aims to overcome the deficiencies of the prior art and provide a composite functional layer for building sound and heat insulation and a preparation process thereof. The core purpose is to systematically solve the combination and assembly problems faced by the hole type gradient foam metal as a building functional layer through special interface design and system interface design.

[0006] (II) Technical solutions To achieve the above-mentioned purpose, the present application adopts the following technical solutions: In a first aspect, the present application provides a composite functional layer 400 for building sound and heat insulation, characterized in that it comprises: a foam metal plate 100 having a hole type gradient, the foam metal plate 100 comprising a surface open hole region 101 and an internal closed hole region 102; At least one open surface of the foam metal board 100 is a rough surface 401 that is bonded to the concrete slurry. The composite functional layer 400 is provided with a plurality of connecting keys 403 that penetrate through itself; The periphery of the composite functional layer 400 is also provided with a connecting structure 402 for splicing between blocks.

[0007] 1. Preferably, the rough surface 401 is a microgroove structure with an arithmetic mean deviation Ra > 20 μm formed by mechanical or chemical treatment.

[0008] Preferably, the connecting key 403 is rod-shaped, nail-shaped, or strip-shaped, and its material is metal, high-strength plastic, or composite material.

[0009] Preferably, the connection structure 402 is a tongue and groove joint, tenon and mortise joint, cable tie or bolt connection, or a pre-embedded part is set by welding or bonding.

[0010] Secondly, the present invention provides a process for preparing the composite functional layer 400, characterized by comprising the following steps: P1: Provide a foam metal plate 100 with a pore gradient; P2: The perforated surface of the foam metal board 100 is mechanically or chemically treated to form a rough surface 401; P3: Multiple connecting keys 403 are provided on the foam metal plate 100, penetrating through itself; P4: A connecting structure 402 is processed or provided around the periphery of the foam metal plate 100.

[0011] 2. Preferably, the mechanical treatment in step P2 is sandblasting or wire brush polishing; the chemical treatment is 5-20% alkaline etching.

[0012] Preferably, the connecting key 403 in step P3 is provided by means of implantation, riveting or bonding.

[0013] Preferably, the connection structure 402 in step P4 is formed by machining to form tongue and groove, tenon and mortise, cable tie or bolt connection, or by welding or bonding embedded parts.

[0014] (III) Beneficial Effects Compared with the prior art, the technical solution provided by the present invention has the following significant advantages: 1. Systematic Solution: Through the triple collaborative design of "rough surface 401" (strengthening interface bonding), "through connection key 403" (providing mechanical anchoring), and "peripheral connection structure 402" (realizing block assembly), the industrialization bottlenecks of "cannot be assembled" and "cannot be glued" are systematically solved. 2. Excellent interface performance: The micro-grooves (Ra>20μm) created in the open structure can produce a dual anchoring effect of "micro-mechanical interlocking + macro-pore filling" with cement slurry, which significantly improves the bonding strength, air tightness and waterproofness. 3. Highly efficient construction and assembly: The design of the connecting key and connection structure enables this functional layer to be firmly anchored to the main building structure and to achieve rapid and precise splicing between blocks, preventing the blocks from peeling off from the main building structure, which greatly improves construction efficiency and system reliability. Attached Figure Description

[0015] Figure 1 This is a three-dimensional structural diagram of the composite functional layer of the present invention; Figure 2 This is a cross-sectional schematic diagram of the composite wall formed by combining the composite functional layer of the present invention with concrete.

[0016] Explanation of the labels in the diagram: 100: Foam metal plate with pore gradient; 101: Surface area (open-cell structure); 102: Core area (closed-cell structure); 400: Composite functional layer; 401: Rough surface; 402: Connection structure; 403: Connection key; 500: Concrete layer. Detailed Implementation

[0017] Example 1: Functional layer for cast-in-place concrete beams

[0018] 1. Provide foam metal board 100: Prepare a gradient foam aluminum board with an overall thickness of 30 mm and a surface open area 101 thickness of 5 mm (open area ratio of 87%).

[0019] 2. Surface treatment (P2): The surface of the opening is sandblasted (using 80-mesh diamond abrasive, pressure 0.5MPa) to form a rough surface 401 with Ra≈25μm.

[0020] 3. Set the connecting key (P3): Insert a Φ6mm glass fiber rod into the plate plane as the connecting key 403, with a longitudinal and transverse spacing of 500mm.

[0021] 4. Set up connection structure (P4): The male and female tongue and groove are machined around the plate to serve as connection structure 402.

[0022] 5. Application: The prepared functional layer 400 is used as the beam side formwork, and the end of the connecting key 403 extends into the beam reinforcement cage. Concrete 500 is then poured. After molding, the functional layer is firmly bonded to the beam, effectively preventing cold bridging.

[0023] Example 2: Functional layer for reinforcing existing exterior walls

[0024] 1. Provide foam metal board 100: using gradient foam aluminum board with an overall thickness of 20mm.

[0025] 2. Surface treatment (P2): Etch with 15% NaOH solution for 15 minutes to form a uniform rough surface 401.

[0026] 3. Set the connecting key (P3): Insert a threaded nylon sleeve into the plate plane as the connecting key 403.

[0027] 4. Set up connection structure (P4): Weld stainless steel embedded parts at the four corners of the plate as connection structure 402.

[0028] 5. Application: Drill holes in the existing exterior wall surface, apply structural adhesive, anchor the functional layer 400 to the wall via connecting key 403 and connecting structure 402, and then cover the rough surface 401 with crack-resistant mortar.

Claims

1. A composite functional layer (400) for sound and heat insulation in buildings, characterized in that, include: A foam metal plate (100) with a pore gradient, the foam metal plate (100) including a surface open area (101) and an internal closed area (102). At least one open surface of the foam metal board (100) is a rough surface (401) that is bonded to the concrete slurry. The composite functional layer (400) is provided with multiple connecting keys (403) that run through it and are used for anchoring to the main building structure. The periphery of the composite functional layer (400) is also provided with a connecting structure (402) for splicing between adjacent functional layer blocks.

2. The composite functional layer (400) according to claim 1, characterized in that, The rough surface (401) is a micro-groove structure with an arithmetic mean deviation Ra>20μm formed by mechanical or chemical treatment.

3. The composite functional layer (400) according to claim 1, characterized in that, The connecting key (403) is rod-shaped, nail-shaped, or strip-shaped.

4. The composite functional layer (400) according to claim 1, characterized in that, The connection structure (402) is a tongue and groove joint, a tenon and mortise joint, or a pre-embedded part.

5. A process for preparing the composite functional layer (400) as described in any one of claims 1-4, characterized in that, Includes the following steps: Provide a foam metal plate (100) with a pore gradient; The perforated surface of the foam metal plate (100) is mechanically or chemically treated to form a rough surface (401). Multiple connecting keys (403) are provided on the foam metal plate (100) through itself; A connecting structure (402) is processed or provided around the periphery of the foam metal plate (100).

6. The process according to claim 5, characterized in that, The mechanical treatment is sandblasting or wire brush polishing; the chemical treatment is etching with an alkaline solution of 5-20% concentration.

7. The process according to claim 5, characterized in that, The connecting key (403) is provided by means of implantation, riveting or bonding.

8. The process according to claim 5, characterized in that, The connection structure (402) is formed by machining into tongue and groove, tenon and mortise, cable tie or bolt connection, or by welding or bonding embedded parts.

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