Composite material with fireproof and soundproof functions, preparation method, application and fireproof and soundproof door thereof

Abstract

The present application relates to a kind of composite material with fireproof sound insulation function and its preparation method, application and fireproof sound insulation door, belong to building material technical field.The raw material of the composite material includes by weight parts: the solid powder material including metakaolin and slag powder 100 parts, modified elastic damping microsphere 5-25 parts, flame-retardant filler 10-40 parts and alkaline activator solution.The alkaline activator solution is used to stimulate solid powder material reaction, forms inorganic gel matrix.The preparation method of the composite material includes: solid powder material, flame-retardant filler and alkaline activator solution are mixed to pulp, then mixed with modified elastic damping microsphere to obtain composite slurry, finally solidification is formed.The present application is synergized by the above raw materials, so that the material has A1 grade fireproof, high damping loss factor and good mechanical strength simultaneously, especially suitable as the door core material of fireproof sound insulation door.The fireproof sound insulation door product made of the material, after international standard test, the weighted sound reduction Rw can reach 55 dB, and the comprehensive performance is excellent.

Description

Technical Field

[0001] This invention relates to the field of building materials technology, specifically to a composite material with fireproof and soundproof functions, its preparation method, application, and fireproof and soundproof door. Background Technology

[0002] In the field of modern building safety and acoustic environment, fire resistance and sound insulation are two core performance requirements that are often mutually restrictive. Currently, most mainstream fireproof and soundproof doors on the market use inorganic filling materials such as rock wool, glass wool, and expanded perlite boards for their cores. Although these materials can meet the Class A non-combustible fire resistance standard, their sound insulation mechanism mainly relies on the absorption of sound energy by their porous structure, and their blocking effect on mid- and low-frequency noise is generally poor, becoming a major bottleneck in improving the overall sound insulation performance of the door. In addition, these traditional filling materials also have problems such as easy settling or pulverization leading to cavities after long-term use, weak bonding strength with the door panel, and difficulty in completely filling complex structural cavities, affecting the long-term reliability, structural integrity, and design flexibility of the product.

[0003] Therefore, developing a new integrated door core material that can take into account the highest level of fire safety, excellent sound insulation performance (especially in the mid and low frequency range), good mechanical strength and lightweight characteristics is of great significance for promoting the upgrading and development of high-performance building protection products. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a composite material with fireproof and soundproof functions, its preparation method, application, and fireproof and soundproof door.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: In a first aspect, the present invention provides a composite material with fireproof and soundproof functions, the raw materials of which, by weight, include the following components: 100 parts of solid powder containing metakaolin and slag powder, 5-25 parts of modified elastic damping microspheres, 10-40 parts of flame-retardant filler, and an alkaline activator solution for activating the solid powder.

[0006] The fire-resistant and sound-insulating composite material provided by this invention is obtained by compounding and curing alkali-activated solid powder, modified elastic damping microspheres, and flame-retardant fillers in a specific ratio. The solid powder contains metakaolin and slag powder, which can undergo an alkali-activated geopolymerization reaction under the stimulation of a water glass solution (this reaction is a well-known process for converting aluminosilicate raw materials into a three-dimensional network inorganic polymer), forming an inorganic gel matrix with a micro-nano porous structure. This not only provides the material with a robust Class A fire-resistant framework but also lays the foundation for its sound insulation and mechanical properties. Based on this principle, this invention achieves room-temperature curing of the material.

[0007] Secondly, to address the inherent drawback of insufficient damping performance in the inorganic gel matrix, elastic damping microspheres modified with a silane coupling agent are introduced. These microspheres act as "microscopic vibration dampers" within the matrix, consuming and dispersing sound waves and vibrational energy through their own deformation, thereby significantly improving the mid-to-low frequency sound insulation effect of the material. Importantly, the surface modification of the microspheres significantly enhances their interfacial compatibility and bonding force with the inorganic gel matrix, enabling the two to form a robust composite. This not only ensures the efficient transfer of damping performance but also directly enhances the overall mechanical strength and durability of the composite material. Meanwhile, the added flame-retardant filler further strengthens the material's fire barrier. Aluminum hydroxide (ATH) is preferred as the flame-retardant filler because it has good compatibility with the alkali-activated system and is key to synergistically achieving and maintaining the material's highest A1 fire rating.

[0008] Importantly, these components achieve synergistic effects through specific design and treatment. Surface modification of the elastic damping microspheres is key to this synergy, significantly improving the compatibility and bonding strength between the microspheres and the inorganic gel matrix, ensuring efficient stress and energy transfer. This not only allows the microspheres to fully exert their damping and sound insulation performance but also directly enhances the overall mechanical strength and durability of the composite material. Ultimately, the inorganic gel matrix provides fire resistance and structural rigidity, the modified elastic microspheres contribute damping and sound insulation properties, and the flame-retardant filler reinforces the fire safety barrier. The synergistic effect of these three components resolves the technical contradictions that traditional materials struggle to achieve simultaneously, enabling the composite material to unify high fire resistance (A1 grade) and high sound insulation performance.

[0009] As a preferred embodiment of the composite material of the present invention, based on a total weight of 100 parts of solid powder, metakaolin is 70-90 parts and slag powder is 10-30 parts.

[0010] In a preferred embodiment of the composite material of the present invention, the alkaline activator solution is a water glass solution with a modulus of 1.2-1.8; the amount of water glass solution used should be such that the ratio of the total water content to the total mass of the solid raw materials in the slurry formed after mixing all the raw materials is 0.28-0.35.

[0011] By limiting the modulus of the water glass solution to 1.2-1.8 and controlling its dosage to achieve a water-to-solid ratio of 0.28-0.35, this invention can effectively regulate the kinetics of the alkali-activated reaction, enabling the slurry to obtain suitable workability and operating time, ensuring the uniform dispersion of components such as modified elastic damping microspheres, and simultaneously enabling the composite material to obtain good early strength and final mechanical properties, avoiding defects such as cracking.

[0012] In a preferred embodiment of the composite material of the present invention, the elastic damping microspheres are acrylate rubber microspheres or silicone rubber microspheres; and / or, the average particle size of the elastic damping microspheres is 50-300 μm; and / or, the silane coupling agent is selected from KH550 and / or KH570.

[0013] In a preferred embodiment of the composite material of the present invention, the flame-retardant filler is aluminum hydroxide; the average particle size D50 of the aluminum hydroxide is 1-5 μm.

[0014] Specifically, aluminum hydroxide (ATH) with an average particle size D50 of 1-5 μm was selected as the flame-retardant filler, enabling it to form a highly compatible and uniformly dispersed composite structure with the inorganic gel matrix obtained by alkali activation. This not only ensures that the material obtains and maintains the highest A1 fire rating, but its suitable particle size also helps to optimize the internal structure of the matrix, thereby synergistically improving the overall fire safety and stability of the material.

[0015] As a preferred embodiment of the composite material of the present invention, it further includes 0.2-0.8 parts of polycarboxylate superplasticizer and 0.05-0.2 parts of cellulose ether.

[0016] Specifically, the water-reducing agent effectively improves the fluidity of the slurry, making it easier to cast and mold; while the cellulose ether acts as a water-retaining and thickening agent, preventing the solid components from settling and segregating before curing. The combined use of the two in this invention can effectively improve the stability of the slurry and the molding quality, thereby ensuring the uniformity and density of the internal structure of the final composite material.

[0017] Secondly, the present invention provides a method for preparing the above-mentioned composite material, which includes the following steps: S1. Take the solid powder containing metakaolin and slag powder, the flame retardant filler and the alkaline activator solution according to the formula, and set them aside. S2. The solid powder, flame-retardant filler and alkaline activator solution are mixed to prepare a premixed slurry; S3. The modified elastic damping microspheres are mixed with the premixed slurry to obtain a composite slurry; S4. The composite slurry is molded and cured to obtain the composite material.

[0018] The present invention provides a method for preparing a composite material with fireproof and soundproof functions. The method involves a stepwise process of mixing solid powder, flame-retardant filler and alkaline activator solution to form a slurry, and then compounding elastic damping microspheres. By controlling the mixing intensity, the structural integrity of the elastic damping microspheres and their uniform dispersion in the matrix are ensured.

[0019] In the preparation method, it should be noted that the curing of this composite material does not rely on an added organic curing agent, but is achieved through an alkaline-activated geopolymerization reaction between the alkaline activator solution (water glass solution) and the solid powder. This reaction takes place at room temperature, forming a three-dimensional network inorganic gel structure that firmly binds the components, ultimately resulting in a dense cured body. By controlling the modulus and amount of water glass solution, as well as the temperature and humidity of the curing environment, the reaction process and curing quality can be effectively regulated, thus ensuring a rationally designed and stable preparation process that reliably produces composite material products with consistent performance.

[0020] Preferably, the preparation method may further include adding 0.2-0.8 parts of polycarboxylate superplasticizer and 0.05-0.2 parts of cellulose ether to the mixed system. The preferred timing of addition is as follows: in step S1, the agent is dry-mixed with the solid powder and flame-retardant filler, and then an alkaline activator solution is added. This addition method helps the two additives to disperse uniformly in the dry state. When mixed with the solution, they can more effectively synergistically improve the fluidity and water retention of the slurry, thereby obtaining a composite slurry with better workability and greater stability. This provides favorable conditions for subsequent casting molding and obtaining a composite material with a uniform and dense structure.

[0021] Preferably, the molding method in step S4 is casting into a mold.

[0022] Preferably, the curing process includes standing at 20-40°C and relative humidity >90% for 24-48 hours until it cures and takes shape.

[0023] Preferably, after curing, the process further includes a step of curing under standard conditions of 20±2℃ and relative humidity >95%.

[0024] As a preferred embodiment of the preparation method of the composite material of the present invention, the preparation process of the modified elastic damping microspheres includes: (1) Dissolve the silane coupling agent in an alcohol solvent, add water to hydrolyze it, and obtain the hydrolysate; (2) The elastic damping microspheres are added to the hydrolysate for dispersion treatment; (3) The mixture obtained in step (2) is reacted under heating conditions. After the reaction is completed, the microspheres are separated, washed and dried to obtain the final product.

[0025] The surface modification process using the silane coupling agent described above can effectively improve the surface properties of the original elastic damping microspheres, enabling them to be more uniformly and stably dispersed in the inorganic gel matrix when compounded with alkali-activated premixed slurry. This avoids structural defects caused by microsphere aggregation or poor interfacial compatibility. This lays an important technological foundation for ensuring that the composite material achieves superior sound insulation and mechanical properties.

[0026] Preferably, in step (1), the alcohol solvent is anhydrous ethanol; the weight ratio of the silane coupling agent, alcohol solvent and water is 1:(9-15):(0.01-0.05).

[0027] Preferably, in step (1), the hydrolysis reaction time is 30-60 minutes.

[0028] Preferably, the weight ratio of the elastic damping microspheres to the silane coupling agent is 1:(0.005-0.02).

[0029] Preferably, in step (2), the dispersion treatment is mechanical stirring dispersion and / or ultrasonic dispersion; the rotation speed of the mechanical stirring dispersion is 300-800 rpm and the time is 20-60 minutes; the power of the ultrasonic dispersion is 100-300W and the time is 10-30 minutes.

[0030] Preferably, in step (2), the reaction temperature is 50-80℃ and the reaction time is 1-2 hours.

[0031] Preferably, in step (3), the drying is vacuum drying, and the drying temperature is 60-80℃.

[0032] Thirdly, the present invention provides a fireproof and soundproof door, comprising a door leaf body consisting of an outer panel (1), an inner panel (2) and a composite material door core (3) filled between the two; the composite material door core (3) is made of the aforementioned composite material with fireproof and soundproof functions.

[0033] The fireproof and soundproof door provided by this invention can directly use the aforementioned composite material as the door core, thus possessing Class A fire resistance, high-efficiency sound insulation, and high damping properties, with comprehensive protective performance significantly superior to traditional door products. Furthermore, this composite material can be flexibly molded through casting and curing, easily processed into door core panels of various specifications or directly filled into complex door cavities. This provides a reliable solution for efficiently manufacturing high-performance fireproof and soundproof doors that can flexibly adapt to different design requirements.

[0034] Specifically, refer to Figure 1The fireproof and soundproof door comprises a door leaf body consisting of an outer panel (1), an inner panel (2), and a composite material core (3) disposed between the two. The composite material core (3) is made of the fireproof and soundproof composite material described in the first aspect above. The composite material core (3) can be prefabricated into a board form and installed between the panels, or it can be integrally formed by pouring slurry into the cavity enclosed by the outer panel (1) and the inner panel (2) and curing it. The integral forming process ensures that the composite material core (3) is tightly bonded to the outer panel (1) and the inner panel (2) respectively, without cavities or gaps. This door structure fully utilizes the Class A fireproof and high damping soundproof characteristics of the composite material of the present invention, achieving a unity of product performance and reliability.

[0035] Fourthly, the present invention provides an application of the above-mentioned composite material in the field of building components. Specifically, the building component is selected from fire-resistant and soundproof door cores, partition walls, or ceiling panels.

[0036] Compared with the prior art, the beneficial effects of the present invention are as follows: This invention provides a fire-resistant and sound-insulating composite material, its preparation method, application, and a fire-resistant and sound-insulating door. The composite material is formed by combining solid powder, surface-modified elastic damping microspheres, and preferably aluminum hydroxide flame-retardant filler in a specific ratio. The solid powder is activated by an alkaline solution of water glass to form an inorganic gel matrix with a micro-nano porous structure, constituting the fire-resistant framework of the material. Simultaneously, surface modification allows the elastic damping microspheres to form a strong interface with the matrix, imparting a high damping loss factor while ensuring good compressive strength and low dry density, thereby significantly improving mid-to-low frequency sound insulation performance. The preparation process of this invention adopts a step-by-step approach of first preparing the slurry and then composite microspheres. By controlling the modulus of the activator (1.2–1.8) and the water-to-solid ratio, the reaction is ensured to be controllable, the microspheres are uniformly dispersed, and the cured body is intact. This system relies on an alkali-activated reaction to achieve room-temperature curing, without the need for external organic curing agents or complex heat treatment. The process is stable and energy-saving, and suitable for large-scale production.

[0037] Compared to traditional filling materials such as rock wool and perlite boards, the composite material obtained in this invention shows significant improvements in fire safety (A1 level), mid-to-low frequency sound insulation performance, mechanical strength, and structural integrity. Fire-resistant and soundproof doors with cores made from this composite material achieve a weighted sound insulation (Rw) of up to 55 dB, tested according to BS EN ISO 10140-2:2021 standards. This material can also be flexibly adapted to various door structures through casting, providing a practical material solution for manufacturing highly fire-resistant, highly sound-insulating, lightweight, and structurally reliable fire-resistant and soundproof doors. Attached Figure Description

[0038] Figure 1This is a cross-sectional structural diagram of one embodiment of the fireproof and soundproof door of the present invention; In the diagram: 1. Outer panel; 2. Inner panel; 3. Composite material door core; Figure 2 The image shows the airborne sound insulation performance curve of the composite fireproof and soundproof door in Example 1. Detailed Implementation

[0039] To better illustrate the purpose, technical solution, and advantages of this invention, the invention will be further described below with reference to specific embodiments. The embodiments described below are some, but not all, embodiments of this invention. The embodiments of this invention are used to illustrate the invention, not to limit it. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention. Unless otherwise specified, experimental methods in the following embodiments that do not specify specific conditions are generally performed under conventional conditions or as recommended by the manufacturer. The raw materials and reagents used are commercially available conventional products or products that conform to relevant national / industry standards and are all commercially available.

[0040] The alkaline activator solution of the present invention is a water glass solution with a modulus of 1.2-1.8. As a specific example, commercially available sodium water glass with a solid content of about 38-42% can be used, and the amount used should be such that the ratio of the total water content to the total mass of the solid raw materials in the slurry formed after mixing all the raw materials is 0.28-0.35.

[0041] Example 1 This embodiment provides a composite material with fireproof and sound insulation functions. Its raw material components, by weight, are 100 parts of solid powder (including 80 parts of metakaolin and 20 parts of slag powder), 20 parts of modified elastic damping microspheres, 25 parts of aluminum hydroxide (ATH) with an average particle size D50 of 3 μm, 0.5 parts of polycarboxylate superplasticizer, 0.15 parts of cellulose ether, and about 73 parts of water glass solution with a modulus of 1.5, with a water-solid ratio of 0.30.

[0042] The preparation process of the modified elastic damping microspheres is as follows: KH570 silane coupling agent, anhydrous ethanol, and water were mixed at a weight ratio of 1:12:0.03 and hydrolyzed at room temperature for 40 minutes to obtain a hydrolysate. Acrylic rubber microspheres with an average particle size of 150 μm were added to the hydrolysate, with a weight ratio of acrylate rubber microspheres to silane coupling agent of 1:0.015. The mixture was stirred and dispersed at 500 rpm for 40 minutes. Subsequently, the mixture was reacted at 65 °C for 1.5 hours. After the reaction, the mixture was filtered, and the resulting solid was washed twice with ethanol and dried under vacuum at 70 °C to constant weight to obtain modified elastic damping microspheres.

[0043] This embodiment provides a method for preparing a composite material with fireproof and sound insulation functions, the steps of which are as follows: Weigh out each raw material component, mix metakaolin, slag powder, aluminum hydroxide, polycarboxylate superplasticizer and cellulose ether evenly, add water glass solution with a modulus of 1.5, and stir at 350 rpm for 2 minutes to obtain a uniform premixed slurry; then add modified elastic damping microspheres to the premixed slurry, stir at 500 rpm for 3 minutes until the microspheres are evenly dispersed to obtain a composite slurry; inject the composite slurry into a mold, vibrate slightly to remove large air bubbles, and let it stand for curing at 30℃ and relative humidity >90% for 48 hours before demolding, and then continue to cure under standard curing conditions (20±2℃, humidity >95%) for 7 days to obtain the composite material product of this embodiment.

[0044] Example 2 This embodiment provides a composite material with fireproof and soundproof functions. Its raw material components, by weight, are 100 parts of solid powder (including 70 parts of metakaolin and 30 parts of slag powder), 5 parts of acrylate rubber microspheres, 10 parts of aluminum hydroxide (ATH) with an average particle size D50 of 1 μm, 0.2 parts of polycarboxylate superplasticizer, 0.05 parts of cellulose ether, and about 54 parts of water glass solution with a modulus of 1.2, with a water-to-solid ratio of 0.28.

[0045] The preparation process of the acrylate rubber microspheres is as follows: KH570 silane coupling agent, anhydrous ethanol, and water were mixed at a weight ratio of 1:12:0.03 and hydrolyzed at room temperature for 40 minutes to obtain a hydrolysate. Acrylic rubber microspheres with an average particle size of 150 μm were added to the hydrolysate, with a weight ratio of acrylate rubber microspheres to silane coupling agent of 1:0.015. The mixture was stirred and dispersed at 500 rpm for 40 minutes. Subsequently, the mixture was reacted at 65 °C for 1.5 hours. After the reaction, the mixture was filtered, and the resulting solid was washed twice with ethanol and dried under vacuum at 70 °C to constant weight to obtain acrylate rubber microspheres.

[0046] This embodiment provides a method for preparing a composite material with fireproof and sound insulation functions, the steps of which are as follows: Weigh each raw material component, mix metakaolin, slag powder, aluminum hydroxide, polycarboxylate superplasticizer and cellulose ether evenly, add a metered water glass solution with a modulus of 1.2, and stir at 350 rpm for 2 minutes to obtain a uniform premixed slurry; then add acrylate rubber microspheres to the premixed slurry and stir at 500 rpm for 3 minutes until the microspheres are evenly dispersed to obtain a composite slurry; inject the composite slurry into a mold, gently vibrate to remove large air bubbles, and let it stand for 48 hours under conditions of 30℃ and relative humidity >90% before demolding. Then continue to cure under standard curing conditions (20±2℃, humidity >95%) for 14 days to obtain the composite material product of this embodiment.

[0047] Example 3 This embodiment provides a composite material with fireproof and sound insulation functions. Its raw material components, by weight, are 100 parts of solid powder (including 90 parts of metakaolin and 10 parts of slag powder), 25 parts of acrylate rubber microspheres, 40 parts of aluminum hydroxide (ATH) with an average particle size D50 of 5 μm, 0.8 parts of polycarboxylate superplasticizer, 0.2 parts of cellulose ether, and approximately 97 parts of water glass solution with a modulus of 1.8, with a water-to-solid ratio of 0.35.

[0048] The preparation process of the acrylate rubber microspheres is as follows: KH570 silane coupling agent, anhydrous ethanol, and water were mixed at a weight ratio of 1:12:0.03 and hydrolyzed at room temperature for 40 minutes to obtain a hydrolysate. Acrylic rubber microspheres with an average particle size of 150 μm were added to the hydrolysate, with a weight ratio of acrylate rubber microspheres to silane coupling agent of 1:0.015. The mixture was stirred and dispersed at 500 rpm for 40 minutes. Subsequently, the mixture was reacted at 65 °C for 1.5 hours. After the reaction, the mixture was filtered, and the resulting solid was washed twice with ethanol and dried under vacuum at 70 °C to constant weight to obtain acrylate rubber microspheres.

[0049] This embodiment provides a method for preparing a composite material with fireproof and sound insulation functions, the steps of which are as follows: Weigh out each raw material component, mix metakaolin, slag powder, aluminum hydroxide, polycarboxylate superplasticizer and cellulose ether evenly, add a metered water glass solution with a modulus of 1.8, and stir at 350 rpm for 2 minutes to obtain a uniform premixed slurry; then add acrylate rubber microspheres to the premixed slurry and stir at 500 rpm for 3 minutes until the microspheres are evenly dispersed to obtain a composite slurry; inject the composite slurry into a mold, gently vibrate to remove large air bubbles, and let it stand for curing at 30℃ and relative humidity >90% for 48 hours before demolding, and then continue curing under standard curing conditions (20±2℃, humidity >95%) for 28 days to obtain the composite material product of this embodiment.

[0050] Example 4 This embodiment provides a fireproof and soundproof door, the structure of which can be referred to as follows. Figure 1 The basic structure is shown. Its preparation process is as follows: 1) Preparation of composite slurry: Prepare the composite slurry according to the formulation and preparation method of Example 1; 2) Door assembly and casting: The outer steel panel (1) and inner steel panel (2) are temporarily fixed by the frame to form a mold with a closed cavity; 3) Pour the composite slurry prepared in step 1) into the cavity and promote flow and air bubble discharge by slight vibration; 4) Curing and molding: Let it stand for 48 hours at 30℃ and relative humidity >90% to allow the slurry to fully cure in the cavity and form a composite door core that is tightly bonded to the panel (3). 5) After curing, demold the door and then place the entire door leaf under standard curing conditions (20±2℃, humidity>95%) for 28 days. After curing, the door leaf is then processed and assembled with hardware to obtain the fireproof and soundproof door product of this embodiment.

[0051] Comparative Example 1 This comparative example provides a composite material whose formulation differs from Example 1 in that modified elastic microspheres are not added, while the remaining raw material components, amounts, and preparation methods are the same as in Example 1. That is, modified elastic microspheres are not added during the preparation of the composite material.

[0052] Comparative Example 2 This comparative example provides a composite material whose formulation differs from that of Example 1 only in that it uses an equal amount of acrylic rubber microspheres of the same specifications but without surface modification by silane coupling agent KH570. The remaining raw material components, dosages, and preparation methods are the same as those in Example 1.

[0053] Comparative Example 3 This comparative example provides a composite material whose formulation differs from that of Example 1 only in that: 50 parts of metakaolin and 50 parts of slag powder are used in 100 parts of solid powder, while the remaining raw material components, dosages, and preparation methods are the same as in Example 1.

[0054] Comparative Example 4 A comparative example provides a composite material whose formulation differs from that of Example 1 only in that aluminum hydroxide (ATH) with an average particle size D50 of 3 μm is replaced in equal amounts with magnesium hydroxide (MDH) with a similar average particle size. The remaining raw material components, dosages, and preparation methods are the same as in Example 1.

[0055] Comparative Example 5 This comparative example provides a composite material whose formulation differs from that of Example 1 only in that the modulus of the water glass is adjusted to 1.0, while the remaining raw material components, dosages, and preparation methods are the same as in Example 1.

[0056] Product performance testing Composite material samples prepared in Examples 1, 3, and Comparative Examples 1-5 were cured for 28 days under standard curing conditions (20±2℃, humidity >95%). Dry density and compressive strength were tested according to GB / T 5486 series standards, flammability rating was tested according to GB 8624-2012, and sound absorption coefficient at 500Hz was tested according to GB / T 18696.1-2004 (impedance tube method). Following the general testing methods for instruments and the principles outlined in ASTM D4065, the damping loss factor (tan δ) was tested in single-frequency tensile mode at a frequency of 10 Hz and a temperature of 25±2°C, with the strain amplitude controlled within the linear viscoelastic region of the material. The test results are shown in Table 1 below.

[0057] Table 1

[0058] As can be seen from Table 1, the composite materials prepared in Examples 1 and 3 of this invention all exhibit good compressive strength, A1 fire resistance, and excellent sound insulation potential characterized by high damping loss factor and sound absorption coefficient. Among them, Example 1, with a relatively low dry density (820 kg / m³), simultaneously achieves high compressive strength (8.7 MPa), top-level fire safety rating (A1), and excellent damping performance (tanδ 0.082), demonstrating the best overall performance balance.

[0059] As can be seen from the performance data of Comparative Example 1, its damping loss factor (0.018) and sound absorption coefficient (0.14) are significantly lower than those of Example 1. This is mainly because the material lacks elastic damping microspheres and relies entirely on a rigid inorganic gel matrix. It cannot effectively dissipate sound waves and vibration energy through microscopic viscoelastic deformation, leading to a decrease in the material's inherent sound insulation performance. Simultaneously, its dry density (950 kg / m³) is the highest, further illustrating the important role of elastic damping microspheres in achieving lightweight materials. The data from Comparative Example 2 show that, after adding elastic damping microspheres, the material's damping factor (0.058) and sound absorption coefficient (0.25) are superior to those of Comparative Example 1. However, its compressive strength (5.9 MPa) is significantly lower than that of Example 1 (8.7 MPa). This indicates that simply adding elastic damping microspheres without surface modification cannot form a strong interfacial bond between the microspheres and the inorganic gel matrix. Under stress, stress cannot be effectively transferred at the interface, leading to stress concentration, which easily induces and propagates interfacial microcracks, thus significantly reducing the material's macroscopic load-bearing capacity and long-term durability.

[0060] The data from Comparative Example 3 show that after changing the ratio of metakaolin to slag powder, the compressive strength (5.2 MPa) of the material was significantly lower than that of Example 1, while the dry density (900 kg / m³) was higher, and neither the damping nor the sound absorption performance was optimal. This demonstrates that deviating from the preferred powder ratio of this invention hinders the formation of a uniform and dense alkali-activated gel structure, directly leading to a loose material structure, insufficient early strength development, and impaired acoustic function. The optimized powder ratio within the scope of this invention is a prerequisite for forming a uniform and dense structure and ensuring basic mechanical and acoustic performance.

[0061] The performance data from Comparative Example 4 show that its flammability rating dropped to A2. This indicates that in the alkali-activated gel system of this invention, aluminum hydroxide (ATH) is the key flame-retardant filler for achieving the highest A1 fire resistance rating. Magnesium hydroxide (MDH), due to its high decomposition temperature, has insufficient initial flame-retardant efficiency in this specific reaction system and cannot achieve the same fire safety rating.

[0062] The data from Comparative Example 5 show that when the modulus of water glass is lower than the preferred range of this invention, the compressive strength (6.0 MPa) of the resulting material is low, and during actual preparation, the workability of the slurry is rapidly lost, and microcracks easily appear in the samples. This is because an excessively low modulus leads to an overly vigorous alkali-activated reaction, causing the reaction process to become uncontrolled and the slurry to solidify rapidly. This prevents the chemical shrinkage stress and thermal stress generated during the reaction from being released in time through deformation while the material is still plastic, and internal air bubbles also cannot be expelled in time. This directly results in an increase in internal defects (high residual stress, numerous air bubbles, etc.), uneven solidification, and a decrease in mechanical properties and durability.

[0063] In summary, the composite material provided by the embodiments of the present invention, through the synergistic effect of a specific ratio of alkali-activated powder, surface-modified elastic damping microspheres, and preferred aluminum hydroxide flame-retardant filler, achieves a balance between high compressive strength and low dry density while ensuring A1 fire resistance and high sound insulation performance, thus achieving a unity of high strength and lightweight, making it an ideal core material for high-performance fireproof and soundproof doors.

[0064] Application examples The fireproof and soundproof door prepared in Example 4 was placed in an acoustic laboratory (test opening 2060 mm × 2500 mm) conforming to the requirements of the BS EN ISO 10140 series standards. Laboratory tests were conducted according to the BS EN ISO 10140-2:2021 standard. The main results are shown in Table 2 below. Figure 2 As shown.

[0065] Table 2

[0066] Note: Test standard: BS EN ISO 10140-2:2021 (Laboratory measurement of airborne sound insulation of building components). Rating according to BS EN ISO 717-1:2020 standard, the weighted sound insulation Rw of this fireproof and soundproof door is measured to be 55dB. Based on the test data in Table 2 and the attached figures Figure 2 As shown in the performance curves, the fireproof and soundproof door made using the composite material of Embodiment 1 of this invention as the core has a weighted sound insulation Rw of 55 dB as measured according to BS EN ISO 10140-2:2021 standard (see the test report in the substantive examination reference materials submitted with this application, report number G22076AC256091). In the critical mid-low frequency range (e.g., 500 Hz), the sound insulation reaches as high as 55.0 dB, and the sound insulation curve shows a balanced performance with no significant weak points throughout the entire test frequency range of 100-5000 Hz. This result demonstrates that the composite material provided by this invention can effectively endow the door product with excellent and comprehensive airborne sound insulation performance, and its overall sound insulation level meets the stringent acoustic requirements of the market for high-performance fireproof and soundproof doors.

[0067] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the scope of protection of the present invention. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the essence and scope of the technical solutions of the present invention.

Claims

1. A composite material with fireproof and soundproof functions, characterized in that, By weight, the raw materials include the following components: 100 parts of solid powder containing metakaolin and slag powder, 5-25 parts of modified elastic damping microspheres, 10-40 parts of flame retardant filler, and an alkaline activator solution for activating the solid powder.

2. The composite material as described in claim 1, characterized in that, Based on a total weight of 100 parts of the solid powder, the portion of metakaolin is 70-90 parts and the portion of slag powder is 10-30 parts.

3. The composite material as described in claim 1 or 2, characterized in that, The alkaline activator solution is a water glass solution with a modulus of 1.2-1.8; the amount of water glass solution used should be such that the ratio of the total water content to the total mass of the solid raw materials in the slurry formed after mixing all the raw materials is 0.28-0.

35.

4. The composite material as described in claim 1 or 2, characterized in that, The elastic damping microspheres are acrylate rubber microspheres or silicone rubber microspheres; and / or, the average particle size of the elastic damping microspheres is 50-300 μm; and / or, the silane coupling agent is selected from KH550 and / or KH570.

5. The composite material as described in claim 1 or 2, characterized in that, The flame-retardant filler is aluminum hydroxide; the average particle size D50 of the aluminum hydroxide is 1-5 μm.

6. The composite material as described in claim 1 or 2, characterized in that, It also includes 0.2-0.8 parts of polycarboxylate superplasticizer and 0.05-0.2 parts of cellulose ether.

7. A method for preparing the composite material according to any one of claims 1-6, characterized in that, Includes the following steps: S1. Take the solid powder containing metakaolin and slag powder, the flame retardant filler and the alkaline activator solution according to the formula amount, and set aside for later use; S2. The solid powder, flame-retardant filler and alkaline activator solution are mixed to prepare a premixed slurry; S3. The modified elastic damping microspheres are mixed with the premixed slurry to obtain a composite slurry; S4. The composite slurry is molded and cured to obtain the composite material.

8. The preparation method according to claim 7, characterized in that, The preparation process of the modified elastic damping microspheres includes: (1) Dissolve the silane coupling agent in an alcohol solvent, add water to hydrolyze it, and obtain the hydrolysate; (2) The elastic damping microspheres are added to the hydrolysate for dispersion treatment; (3) The mixture obtained in step (2) is reacted under heating conditions. After the reaction is completed, the microspheres are separated, washed and dried to obtain the final product.

9. A fireproof and soundproof door, characterized in that, The door body comprises an outer panel (1), an inner panel (2), and a composite material core (3) filled between the two; the composite material core (3) is made of a fireproof and soundproof composite material as described in any one of claims 1-6.

10. The application of the composite material according to any one of claims 1-6 in the field of building components, wherein the building components are selected from fireproof and soundproof door cores, partition walls or ceiling panels.

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