Lightweight heat-preservation sound-insulation floor material and preparation method thereof

Abstract

The invention belongs to the technical field of building materials, and particularly relates to a light heat preservation and sound insulation material and a preparation method thereof. The light heat preservation and sound insulation material comprises a component A and a component B, wherein the mass ratio of the component A to the component B is (2-4): 1; the component A comprises light particles, sound insulation particles, mixed sand, fly ash floating beads and ceramsite sand; the component B comprises an inorganic gel material, anti-crack fibers and an additive. When in use, the component A and the component B are mixed, added with water and uniformly stirred to form the mortar capable of being directly paved. By optimizing the raw materials and the ratio of the raw materials, the heat-insulating and sound-insulating material has the comprehensive properties of light weight, excellent heat-insulating and sound-insulating properties, good pressure resistance, crack resistance, durability and the like, can effectively block the transmission of impact sound and air sound, controls the heat transfer coefficient, meets the requirements of different structures of a sound-insulating and heat-insulating layer, a protective layer and the like of an HTK sound-insulating floor system, and has a good application prospect. And an integrated sound insulation and heat preservation solution is provided for the building floor.

Description

A lightweight thermal insulation and soundproof flooring material and its preparation method Technical Field

[0001] This invention belongs to the field of building materials technology, specifically relating to a lightweight thermal insulation and sound insulation material and its preparation method. Background Technology

[0002] As residents' demands for building comfort increase, the sound insulation and thermal insulation performance of floors have become core indicators for measuring building quality, directly impacting the living experience. In residential and office buildings, impact sounds (walking, furniture movement, etc.) and airborne noise are easily transmitted through floors, causing noise pollution. Simultaneously, floor heat loss is a significant portion of building energy consumption; insufficient insulation increases energy consumption, which is inconsistent with green building trends. Therefore, developing materials and integrated construction systems that combine excellent sound insulation, thermal insulation, and structural performance is an urgent need in the field of building sound insulation and thermal insulation.

[0003] To address this need, lightweight sound-insulating mortar has emerged. It is composed of lightweight aggregates and cementitious materials, offering convenient construction and achieving sound insulation through its porous structure. It has been gradually applied in engineering projects. Existing products are categorized by density into HTKA, HTKB (standard), and HTKC (high-strength) types to suit different structural requirements, forming the HTK sound-insulating floor system. This system is an integral structure, comprising a concrete base layer, a sound insulation layer, and a protective layer from top to bottom. It aims to achieve dual functions of sound insulation and thermal insulation through synergistic action, theoretically achieving a weighted standardized impact sound pressure level ≤70 dB while controlling the heat transfer coefficient.

[0004] However, existing lightweight sound-insulating mortars and HTK systems have many shortcomings in practical applications, making it difficult to meet the needs of high-quality projects. Specifically, these shortcomings include: most existing products are single-formula, resulting in a contradiction between lightweight and high strength, and an imbalance between thermal insulation and sound insulation. Excessive addition of lightweight aggregates reduces compressive strength, making it unsuitable for HTKC-type surface layers; adding cementitious materials increases dry density, weakening the thermal insulation and sound insulation effect, especially in terms of insufficient low-frequency impact sound blocking, making it difficult to meet the differentiated needs of ordinary and high-strength types.

[0005] Existing products have a high drying shrinkage rate, and during the hardening process, micro-cracks are easily generated due to temperature changes and heat of hydration, which damages the overall integrity and reduces the sound insulation and heat preservation effect. Cracks can also allow moisture to penetrate, exacerbating performance degradation and shortening service life. Moreover, existing products mostly use a single crack-resistant fiber, which has limited dispersibility and stress dispersion capabilities, and cannot fundamentally solve the cracking problem.

[0006] Low-frequency impact sounds (such as footsteps) travel far and attenuate slowly, causing significant interference. Existing materials rely on porous sound insulation, which is ineffective at blocking low-frequency sound waves. The core reason is the lack of an effective damping and vibration reduction mechanism, which fails to convert the mechanical energy of low-frequency vibrations into heat energy for dissipation, making it difficult to meet the sound insulation requirements of high-comfort buildings.

[0007] In addition, the composition of lightweight sound insulation mortar lacks systematic optimization, and the selection and dosage of raw materials are inappropriate, resulting in insufficient bonding force between the material and each layer of the HTK system, making it easy to delaminate and fall off.

[0008] In summary, existing lightweight sound insulation materials suffer from poor performance synergy, insufficient crack resistance and durability, poor low-frequency sound insulation, and unsatisfactory adaptability and economy, making them unsuitable for the integrated requirements of HTK systems and unable to provide stable and reliable sound insulation and thermal insulation solutions. Therefore, developing materials that combine lightweight properties, excellent thermal and sound insulation, compressive and crack resistance, and durability, while adapting to different structural requirements, is a pressing technical challenge that needs to be addressed in this field. Summary of the Invention

[0009] Based on the above technical background, the main objective of this invention is to provide a lightweight thermal insulation and sound insulation material and its preparation method, so as to overcome the shortcomings of the prior art.

[0010] To achieve the aforementioned objective, the technical solution adopted by the present invention includes: The first aspect of the present invention is to provide a lightweight thermal insulation and sound insulation material, wherein the lightweight thermal insulation and sound insulation material comprises component A and component B, and the mass ratio of component A to component B is (2-4):1.

[0011] Preferably, the mass ratio of component A to component B is 3:1.

[0012] The A component includes: lightweight particles, sound-insulating particles, mixed sand, fly ash cenospheres, and ceramsite sand.

[0013] Component B includes inorganic gel materials, crack-resistant fibers, and additives.

[0014] According to a preferred embodiment of the present invention, component A is prepared from the following raw materials in parts by weight: 10-25 parts by weight of lightweight particles; 5-15 parts by weight of sound-insulating particles; 10-20 parts by weight of mixed sand; 10-20 parts by weight of fly ash cenospheres; and 30-50 parts by weight of ceramsite sand.

[0015] Preferably, component A is prepared from the following raw materials in parts by weight: 20 parts by weight of lightweight particles; 10 parts by weight of sound-insulating particles; 15 parts by weight of mixed sand; 15 parts by weight of fly ash cenospheres; and 40 parts by weight of ceramsite sand.

[0016] According to a preferred embodiment of the present invention, component B is prepared from the following raw materials in parts by weight: 100 parts by weight of inorganic cementitious material; 0.2 to 0.5 parts by weight of crack-resistant fiber; and 2 to 5 parts by weight of additives.

[0017] Preferably, component B is prepared from the following raw materials in parts by weight: 100 parts by weight of inorganic cementitious material; 0.3 parts by weight of crack-resistant fiber; and 3 parts by weight of additives.

[0018] The lightweight particles are preferably lightweight ceramic particles.

[0019] The sound-insulating particles are preferably sound-insulating ceramic particles. The lightweight particles and sound-insulating particles used in this invention can effectively reduce the density of lightweight thermal insulation and sound insulation materials and enhance the sound insulation effect of these materials.

[0020] The sand used in this invention can fill the gaps between lightweight particles, ceramsite sand and other raw materials, and increase the density of the material after molding; at the same time, it enhances the interfacial bonding force between component A and component B, and avoids the problem of insufficient strength caused by excessive gaps between aggregates.

[0021] Fly ash cenospheres have a hollow microsphere structure, which can further reduce the material density and improve thermal insulation efficiency; at the same time, the gaps between the microspheres block the transmission of sound waves, and work together with sound-insulating particles to enhance the sound insulation effect; in addition, its chemical inertness can improve the weather resistance of building materials and reduce shrinkage and deformation.

[0022] The ceramsite sand in this invention serves as the aggregate base material of component A, providing structural support. Its high strength and low water absorption characteristics ensure that the material has high compressive strength while remaining lightweight, and at the same time, it can avoid the decline in compressive performance due to insufficient aggregate strength. In addition, its porous structure can help improve the thermal insulation and sound insulation effects, making it suitable for the compressive requirements of "high-strength (HTKC type)" materials.

[0023] The inorganic gel material is selected from one or more of water glass, lime, and cement.

[0024] Preferably, the inorganic gel material is cement, more preferably silicate cement.

[0025] The inorganic gel material, as the core bonding substrate of component B, undergoes a hydration reaction after being stirred with water. This reaction can firmly bind the aggregate particles of component A into a whole, giving the material excellent compressive strength, wear resistance, and structural integrity. The density of its hydration products can further optimize the material's waterproofness, preventing moisture intrusion from affecting its thermal insulation and sound insulation effects.

[0026] The crack-resistant fiber is selected from one or more of steel fiber, glass fiber, basalt fiber, and polypropylene fiber.

[0027] Preferably, the crack-resistant fiber is a composite fiber of steel fiber and polypropylene fiber, wherein the mass ratio of steel fiber to polypropylene fiber is (20-40):1.

[0028] Preferably, the mass ratio of the steel fiber to the polypropylene fiber is 30:1.

[0029] Experiments have shown that the crack-resistant fibers can inhibit drying shrinkage cracks during the material hardening process. Through the uniform dispersion of the fibers in the cementitious material matrix, a three-dimensional network support structure is formed, which can disperse shrinkage stress, reduce the generation of microcracks caused by temperature changes or heat of hydration, improve the crack resistance and durability of the material, and ensure the integrity of the thermal insulation and soundproofing layer (avoiding cracks that lead to failure of sound insulation and thermal insulation effects). Experiments have also shown that when the mass ratio of steel fibers to polypropylene fibers is within the above-mentioned range, it can effectively improve the compressive and impact strength of lightweight thermal insulation and soundproofing materials.

[0030] The additives include water-reducing agents and polypropylene emulsions.

[0031] The water-reducing agent is selected from one or more of lignin sulfonate water-reducing agents and naphthalene-based water-reducing agents.

[0032] Preferably, the water-reducing agent is calcium lignosulfonate.

[0033] The lignin sulfonate is an anionic surfactant, and its molecular structure contains a large number of sulfonic acid groups (-SO3). - Cement contains hydrophilic groups such as lignin sulfonate and hydrophobic groups in its lignin skeleton. When water is added to cement, the particles aggregate due to intermolecular and electrostatic forces, forming a flocculated structure that traps a large amount of water inside, preventing it from flowing. Lignosulfonate molecules are quickly adsorbed onto the surface of cement particles, with the hydrophilic groups facing outwards and the hydrophobic groups facing inwards, giving the cement particle surface a negative charge. Adjacent particles repel each other due to the same charge, breaking the original flocculated structure and releasing the trapped water, thus achieving water reduction and plasticizing effects.

[0034] The polyacrylic acid emulsion used in this invention is a flexible polymer that exhibits good viscoelasticity after drying and forming a film, thus improving the material's crack resistance and durability. Simultaneously, the polyacrylic acid emulsion also imparts a certain degree of damping property to the sound insulation material. When sound waves or vibration energy act on the material, the polymer chains undergo friction and deformation, converting the mechanical energy of the vibration into heat energy for dissipation, rather than reflection or conduction. This damping and vibration reduction effect is particularly effective for low-frequency noise, compensating for the poor low-frequency sound insulation performance of traditional inorganic sound insulation materials (such as cement-based materials).

[0035] The mass ratio of the water-reducing agent to the polypropylene emulsion is 1:(4-15).

[0036] Preferably, the mass ratio of the water-reducing agent to the polypropylene emulsion is 1:10.

[0037] The second aspect of the present invention is to provide a method for using the lightweight thermal insulation and sound insulation material described in the first aspect of the present invention. The method includes: mixing component A and component B, adding water and stirring to form a lightweight thermal insulation and sound insulation mortar, and spreading the mortar evenly on the thermal insulation and sound insulation layer.

[0038] The amount of water added is 20% to 30% of the total weight of components A and B.

[0039] Preferably, the amount of water added is 25% of the total weight of components A and B.

[0040] Component A is obtained by mixing lightweight particles, sound-insulating particles, mixed sand, fly ash cenospheres, and ceramsite sand.

[0041] Component B is obtained by mixing inorganic cementitious materials, crack-resistant fibers and additives.

[0042] The beneficial effects of this invention are as follows: (1) This invention adopts a two-component design of A and B, which not only facilitates production, storage and transportation, but also allows for flexible adaptation to the functional requirements of different building scenarios by adjusting the proportion of A and B components and the amount of raw materials in each component. It can be used as a general product for sound insulation and heat insulation layers and leveling layers of floors, or as a high-strength product for protective surface layers of floors by optimizing the proportion. It undertakes multiple functions of pressure bearing, protection and sound insulation, perfectly adapts to the overall structural requirements of the HTK sound insulation floor system, and provides personalized solutions for different types of building floor projects.

[0043] (2) In the A component of the present invention, by using lightweight particles and sound-insulating particles in combination, combined with the lightweight heat-insulating properties of fly ash cenospheres, the dry density of the material is significantly reduced. At the same time, with the damping properties imparted by polypropylene emulsion, the blocking effect on low-frequency noise can be effectively improved, making up for the shortcomings of traditional inorganic sound insulation materials. By limiting the reasonable component ratio, the material has excellent sound insulation effect and excellent heat insulation performance, realizing the synergistic improvement of heat insulation and sound insulation functions.

[0044] (3) In this invention, ceramsite sand is used as the core of component A. Its high strength and low water absorption provide reliable structural support for the material. Combined with the filling effect of the sand in the aggregate gap and the interface bonding and strengthening effect of components A and B, the material has excellent compressive strength while maintaining its lightweight characteristics. It can be directly adapted to the pressure and protection requirements of high-strength (HTKC type) floor, and can also meet the thermal insulation and sound insulation leveling requirements of ordinary (HTKA, HTKB type), thus broadening the application scenarios of the material.

[0045] (4) The present invention preferably adopts a composite crack-resistant fiber system of steel fiber and polypropylene fiber. Through the three-dimensional network support structure formed by the fiber in the cementitious material matrix, shrinkage stress can be efficiently dispersed, microcracks caused by drying shrinkage and temperature changes can be suppressed, and cracks can be avoided to prevent the failure of thermal insulation and sound insulation effect. At the same time, the viscoelastic structure formed by the polyacrylic acid emulsion in component B after drying into a film can further improve the crack resistance and durability of the material. Combined with the dense and waterproof properties of the hydration products of inorganic cementitious materials, it can effectively resist water intrusion, extend the service life of the material, and solve the common problems of easy cracking and poor durability of existing sound insulation mortar.

[0046] (5) The raw materials selected in the invention are all common and readily available materials in the construction field (such as silicate cement, ceramsite, ordinary sand, etc.), and the fly ash cenospheres, an industrial waste, are used in a reasonable way to realize the resource utilization of waste, reduce the cost of raw materials and reduce the environmental burden; it is in line with the industry development trend of green building and energy conservation and emission reduction. Detailed Implementation

[0047] The present invention will now be described in detail, and its features and advantages will become clearer and more apparent from these descriptions.

[0048] The present invention is further illustrated below by specific examples. These examples are for illustrative purposes only and are not intended to limit the scope of the invention. All raw materials used in the embodiments of the present invention were commercially available.

[0049] Example 1: A lightweight thermal insulation and sound insulation material, comprising component A and component B, wherein the mass ratio of component A to component B is 3:1.

[0050] Component A is made from the following raw materials in parts by weight: 20 parts by weight of lightweight ceramsite, 10 parts by weight of sound-insulating ceramsite, 15 parts by weight of sand, 15 parts by weight of fly ash cenospheres, and 40 parts by weight of ceramsite sand.

[0051] Component B is prepared from the following raw materials in parts by weight: 100 parts by weight of inorganic cementitious silicate cement, 0.3 parts by weight of crack-resistant fiber, and 3 parts by weight of additives.

[0052] The crack-resistant fiber is a composite fiber of steel fiber and polypropylene fiber, wherein the mass ratio of the steel fiber to the polypropylene fiber is 30:1.

[0053] The additives include water-reducing agent calcium lignosulfonate and polypropylene emulsion, wherein the mass ratio of the water-reducing agent to the polypropylene emulsion is 1:10.

[0054] Example 2: A lightweight thermal insulation and sound insulation material, comprising component A and component B, wherein the mass ratio of component A to component B is 2:1.

[0055] Component A is prepared from the following raw materials in parts by weight: 10 parts by weight of lightweight ceramsite, 5 parts by weight of sound-insulating ceramsite, 10 parts by weight of sand, 10 parts by weight of fly ash cenospheres, and 50 parts by weight of ceramsite sand.

[0056] Component B is prepared from the following raw materials in parts by weight: 100 parts by weight of inorganic cementitious silicate cement, 0.2 parts by weight of crack-resistant fiber, and 2 parts by weight of additives.

[0057] The crack-resistant fiber is a composite fiber of steel fiber and polypropylene fiber, wherein the mass ratio of the steel fiber to the polypropylene fiber is 20:1.

[0058] The additives include a water-reducing agent, calcium lignosulfonate, and a polypropylene emulsion, wherein the mass ratio of the water-reducing agent to the polypropylene emulsion is 1:4. Example 3: A lightweight thermal insulation and sound insulation material, comprising component A and component B, wherein the mass ratio of component A to component B is 4:1.

[0059] Component A is made from the following raw materials in parts by weight: 25 parts by weight of lightweight ceramsite, 15 parts by weight of sound-insulating ceramsite, 20 parts by weight of sand, 20 parts by weight of fly ash cenospheres, and 30 parts by weight of ceramsite sand.

[0060] Component B is prepared from the following raw materials in parts by weight: 100 parts by weight of inorganic cementitious silicate cement, 0.5 parts by weight of crack-resistant fiber, and 5 parts by weight of additives.

[0061] The crack-resistant fiber is a composite fiber of steel fiber and polypropylene fiber, wherein the mass ratio of the steel fiber to the polypropylene fiber is 40:1.

[0062] The additives include water-reducing agent calcium lignosulfonate and polypropylene emulsion, wherein the mass ratio of the water-reducing agent to the polypropylene emulsion is 1:15.

[0063] The present invention has been described in detail above with reference to specific embodiments and exemplary examples; however, these descriptions should not be construed as limiting the present invention. Those skilled in the art will understand that various equivalent substitutions, modifications, or improvements can be made to the technical solutions and embodiments of the present invention without departing from the spirit and scope of the invention, and all such modifications and improvements fall within the scope of the present invention. The scope of protection of the present invention is defined by the appended claims.

Claims

1. A lightweight thermal insulation and soundproofing material, characterized in that, The lightweight thermal insulation and sound insulation material comprises component A and component B, wherein the mass ratio of component A to component B is (2-4):1; component A comprises: lightweight particles, sound insulation particles, mixed sand, fly ash cenospheres and ceramsite sand; component B comprises inorganic gel material, crack-resistant fibers and additives.

2. The lightweight thermal insulation and soundproofing material according to claim 1, characterized in that, The mass ratio of component A to component B is 3:

1.

3. The lightweight thermal insulation and soundproofing material according to claim 1, characterized in that, Component A is prepared from the following raw materials in parts by weight: 10-25 parts by weight of lightweight particles; 5-15 parts by weight of sound-insulating particles; 10-20 parts by weight of mixed sand; 10-20 parts by weight of fly ash cenospheres; and 30-50 parts by weight of ceramsite sand.

4. The lightweight thermal insulation and soundproofing material according to claim 1, characterized in that, Component B is prepared from the following raw materials in parts by weight: 100 parts by weight of inorganic cementitious material; 0.2 to 0.5 parts by weight of crack-resistant fiber; and 2 to 5 parts by weight of additives.

5. The lightweight thermal insulation and sound insulation material according to claim 1, characterized in that, The lightweight particles are lightweight ceramic particles; the sound-insulating particles are sound-insulating ceramic particles.

6. The lightweight thermal insulation and sound insulation material according to claim 1, characterized in that, The inorganic gel material is selected from one or more of water glass, lime, and cement; the crack-resistant fiber is selected from one or more of steel fiber, glass fiber, basalt fiber, and polypropylene fiber.

7. The lightweight thermal insulation and sound insulation material according to claim 6, characterized in that, The crack-resistant fiber is a composite fiber of steel fiber and polypropylene fiber, wherein the mass ratio of steel fiber to polypropylene fiber is (20-40):

1.

8. The lightweight thermal insulation and sound insulation material according to claim 1, characterized in that, The additives include water-reducing agents and polypropylene emulsions; the water-reducing agents are selected from one or more of lignin sulfonate water-reducing agents and naphthalene-based water-reducing agents.

9. The lightweight thermal insulation and sound insulation material according to claim 9, characterized in that, The mass ratio of the water-reducing agent to the polypropylene emulsion is 1:(4-15).

10. A method of using the lightweight thermal insulation and soundproofing material according to any one of claims 1 to 9, characterized in that, The method of use includes the following steps: mixing component A and component B, adding water and stirring to form a lightweight thermal insulation and sound insulation mortar, and spreading the mortar evenly on the thermal insulation and sound insulation layer; the amount of water added is 20% to 30% of the total weight of component A and component B.