Foamed aluminum-gypsum composite partition wall with high sound insulation performance

Abstract

This invention relates to the field of sound insulation technology and discloses a foamed aluminum-gypsum composite partition wall with high sound insulation performance. It employs a five-layer symmetrical composite structure: fire-resistant gypsum board, damping sound-insulating adhesive layer, gradient-pore-sized open-cell foamed aluminum core layer, damping sound-insulating adhesive layer, and fire-resistant gypsum board. Because the foamed aluminum core layer and fire-resistant gypsum board are bonded with environmentally friendly polyurethane structural adhesive and fixed with C-shaped cold-rolled galvanized light steel keel, the interlayer bonding is ensured to be firm and the overall rigidity uniform, preventing delamination and deformation during use. The partition wall joints utilize a double-sealing process of sealant and grooves. Internal flame-retardant sealant fills the gaps to block sound bridges and smoke passages, while external U-shaped PVC grooves combined with butyl rubber sound-insulating pads achieve full enclosure, improving long-term stability. It also boasts advantages such as lightweight, high strength, convenient construction, and good durability.

Description

Technical Field

[0001] This invention relates to the field of aluminum foam technology, specifically to an aluminum foam-gypsum composite partition wall with high sound insulation performance. Background Technology

[0002] Building partitions, as core components for dividing interior spaces in modern buildings, are widely used in residential, commercial complexes, and office buildings. With increasing demands for comfort and safety in living and usage environments, partition materials have evolved from traditional solid bricks, blocks, and ordinary gypsum board to lightweight, high-strength, sound-insulating, and fire-resistant materials. Currently, most lightweight partitions on the market are made of single gypsum board, calcium silicate board, or composite lightweight panels, but significant problems still exist in practical applications.

[0003] In terms of acoustic performance, ordinary lightweight partition walls generally have low sound insulation, particularly weak sound insulation in the mid-to-low frequency range, making them unsuitable for use in places with high requirements for quiet environments, such as hotels, hospitals, and residences. While some partition walls improve sound insulation by increasing the number of layers or thickness of panels, this leads to increased weight, space occupation, and construction costs. Furthermore, gaps easily form at the joints of partition walls, becoming major channels for sound wave propagation. Conventional sealing methods have poor durability, resulting in rapid degradation of sound insulation performance over long-term use.

[0004] In terms of fire resistance and structural stability, traditional lightweight partition walls have a single flame-retardant component, which is prone to softening and pulverizing at high temperatures, making it difficult to consistently meet Class A fire resistance requirements. In addition, commonly used partition walls are mostly homogeneous solid structures, lacking internal damping dissipation and gradient buffering designs, making them prone to structural sound transmission when subjected to impacts or vibrations, resulting in insufficient overall mechanical properties and dimensional stability.

[0005] Based on this, the present invention proposes a foamed aluminum-gypsum composite partition wall with high sound insulation performance to solve the corresponding problems. Summary of the Invention

[0006] To address the problems in the prior art, the present invention provides a foamed aluminum-gypsum composite partition wall with high sound insulation performance.

[0007] The technical solution adopted by this invention to solve its technical problem is: a foamed aluminum-gypsum composite partition wall with high sound insulation performance, which adopts a five-layer symmetrical composite structure of fire-resistant gypsum board, damping sound insulation bonding layer, gradient pore size open-cell foamed aluminum core layer, damping sound insulation bonding layer, and fire-resistant gypsum board; the thickness of the gradient pore size open-cell foamed aluminum core layer is 40-80mm, the porosity is 80%-90%, the surface pore size is 100-300μm, and the internal pore size is 500-800μm; the damping sound insulation bonding layer is... The partition wall uses a 2-3mm thick butyl damping sound insulation adhesive; the fire-resistant gypsum board is 12-15mm thick; the aluminum foam core layer is bonded to the fire-resistant gypsum board with environmentally friendly polyurethane structural adhesive and fixed by C-shaped cold-rolled galvanized light steel keel with a center-to-center spacing of 400-600mm; the joints of the partition wall use a double sealing process of sealant and slots; the partition wall has an airborne sound insulation of 45-55dB in the 50-1000Hz frequency band and a self-weight of 30-50kg / m² in a dry state. 2 The overall fire resistance rating reaches Class A.

[0008] As a further technical solution, the fire-resistant gypsum board is made from the following raw materials by weight percentage: 3-4 wt% glass fiber, 5-8 wt% expanded perlite, 17-20 wt% aluminum hydroxide / magnesium hydroxide composite inorganic flame retardant, and the remainder being building gypsum. The preparation method is as follows: mix evenly at 300-500 r / min for 10-15 min according to the formula, press under 5-8 MPa pressure for 1-2 min to form, steam cure at 80-90℃ for 4-6 h, and dry at 100-110℃ until the moisture content is ≤1.5%.

[0009] As a further technical solution, the mass ratio of aluminum hydroxide to magnesium hydroxide in the aluminum hydroxide / magnesium hydroxide composite inorganic flame retardant is 1:4.

[0010] As a further technical solution, the damping resin in the butyl damping sound insulation adhesive is a phenolic modified epoxy damping resin, which is prepared by mixing 100 parts of epoxy resin, 35-45 parts of phenolic resin, 8-12 parts of methyl hexahydrophthalic anhydride curing agent, and 0.5-1 parts of dibutyltin dilaurate catalyst, stirring at 200-300 r / min, reacting at 120-130℃ for 2-3 h, and cooling at 5-10℃ / min to 25±5℃ to obtain the modified damping resin.

[0011] As a further technical solution, the butyl damping sound insulation adhesive is composed of 30-32wt% calcium carbonate filler, 15-18wt% of the above-mentioned modified damping resin, 15-17wt% antioxidant 264, and the balance butyl rubber. It is formed by mixing at 100-120℃ for 15-20min, calendering at 80-100℃ to a thickness tolerance of ±0.1mm, and coating at 60-80℃ at a rate of 0.8-1.2m / min.

[0012] As a further technical solution, the gradient pore size open-cell aluminum foam core layer uses industrial pure aluminum ≥99.5wt% as the matrix and titanium dihydrogen 200-300 mesh as the foaming agent, and is prepared by directional melt foaming process: the aluminum melt is heated to 680-720℃, 0.8-1.2wt% titanium dihydrogen hydrate is added, the temperature is held for 3-5 minutes under directional pressure of 0.1-0.3MPa, and the mold is cooled to below 50℃ at a rate of 10-15℃ / min to form the core.

[0013] As a further technical solution, the environmentally friendly polyurethane structural adhesive is a single-component polyurethane structural adhesive with a solid content ≥95%, room temperature moisture curing, and tensile shear strength ≥1.2MPa, and the application thickness is 0.2-0.5mm.

[0014] As a further technical solution, the double sealing process is as follows: the inside of the splice joint is continuously and fully filled with FV-0 grade silicone flame-retardant sealant with an application pressure of 0.2-0.3MPa; the outside of the splice joint is covered with a PVC groove with a wall thickness of 1.5mm, FV-0 grade, and a U-shaped cross section of 50mm×15mm with a clamping pressure of 0.1-0.2MPa; a 1mm thick FV-0 grade butyl rubber sound insulation pad is hot-pressed onto the inner wall of the groove and fits seamlessly with the surface of the partition wall, so as to achieve a fully sealed splice joint to prevent sound leakage.

[0015] As a further technical solution, the partition wall is a standardized modular unit, with a single module having a planar size of 1200mm×2400mm and a module thickness consistent with the total thickness of the five-layer symmetrical composite structure; the vertical and horizontal splicing seams of the modular unit adopt the double sealing process of the sealant and the slot.

[0016] The method for preparing the composite partition wall is as follows: (1) Prepare refractory gypsum board, butyl damping sound insulation adhesive, and gradient pore size foam aluminum core layer according to the method described above; (2) Apply 2-3 mm butyl damping sound insulation adhesive evenly to the inside of the refractory gypsum board at 60-80℃ and a speed of 0.8-1.2 m / min; (3) Apply the environmentally friendly polyurethane structural adhesive to the adhesive-coated surface of the refractory gypsum board, with an adhesive thickness of 0.2-0.5 mm; (4) Align and bond the aluminum foam core layer with the plasterboard on both sides, and pressurize at 0.1-0.2MPa for 10-15 minutes at room temperature of 25±5℃ to complete the bonding and molding; (5) Install C-type cold-rolled galvanized light steel keel at a spacing of 400-600mm, and nest the keel and the foam aluminum core layer at a depth of 5-10mm, and fasten with Φ4.8mm galvanized self-tapping screws at a spacing of 150-200mm; (6) Fill the joint of the partition wall with FV-0 grade silicone flame retardant sealant and wrap the U-shaped PVC groove with a clamping pressure of 0.1-0.2MPa to complete the double seal; (7) The whole thing is left to stand at 25±5℃ for 24 hours to cure. After the sound insulation and fire resistance are tested and found to be qualified, it is ready to leave the factory.

[0017] The beneficial effects of this invention are: 1. This invention employs a five-layer symmetrical composite structure: fire-resistant gypsum board, damping and sound-insulating adhesive layer, gradient-pore-sized open-cell aluminum foam core layer, damping and sound-insulating adhesive layer, and fire-resistant gypsum board. This allows each functional layer to perform its specific function while working synergistically, achieving an overall performance improvement from the perspectives of materials, structure, and process. Because the fire-resistant gypsum board utilizes a composite flame-retardant system of glass fiber, expanded perlite, and aluminum hydroxide / magnesium hydroxide, the glass fiber forms a mesh-like reinforcing structure within the gypsum matrix, enhancing the board's bending and impact resistance. Expanded perlite reduces the board's weight and increases internal porosity, optimizing its basic heat insulation and sound absorption properties. The combination of aluminum hydroxide and magnesium hydroxide decomposes stepwise at high temperatures, absorbing heat, releasing inert gases, and forming a dense ceramic barrier layer. This gives the gypsum board a stable Class A fire resistance, thus solving the problems of low flame-retardant efficiency and easy high-temperature failure in traditional gypsum boards.

[0018] 2. The damping and sound-insulating bonding layer uses a compound system of phenolic modified epoxy damping resin and butyl rubber. The modified damping resin can improve the loss factor of the bonding layer and enhance the energy dissipation capacity of mid-to-low frequency vibrations. The butyl rubber provides good flexibility and sealing properties, and with a thickness design of 2-3mm, it can effectively block sound transmission between layers. At the same time, the gradient pore size open-cell aluminum foam core layer adopts a directional foaming structure with small pores on the surface and large pores inside. The small-pore surface reflects and dissipates mid-to-high frequency sound waves, while the large-pore interior absorbs and attenuates low-frequency sound waves. Combined with a high porosity of 80%-90%, it further improves the sound wave loss efficiency. The above structure and materials work together to make the sound waves undergo multiple effects of reflection, dissipation, and absorption during transmission, so that the airborne sound insulation of the partition wall can stably reach 45-55dB in the 50-1000Hz frequency band, thereby solving the problems of poor mid-to-low frequency sound insulation and insufficient sound insulation in traditional lightweight partition walls.

[0019] 3. Because the aluminum foam core layer and fire-resistant gypsum board are bonded using environmentally friendly polyurethane structural adhesive, and fixed with C-shaped cold-rolled galvanized light steel keel, a strong interlayer bond and uniform overall rigidity are ensured, preventing delamination and deformation during use. The partition wall joints employ a double-sealing process using sealant and slots. Internal flame-retardant sealant fills gaps to block sound bridges and smoke passages, while external U-shaped PVC slots combined with butyl rubber sound insulation pads achieve complete enclosure, enhancing long-term stability. The overall solution adopts a modular design and standardized manufacturing process, with each component and process parameter matched to achieve high sound insulation and Class A fire resistance, while maintaining a dry weight of 30-50 kg / m². 2 It combines the advantages of being lightweight, high-strength, easy to construct, and durable, fundamentally solving a series of problems such as insufficient sound insulation, poor fire resistance, unreasonable self-weight, sealing failure, and complex installation of existing partition walls. It has good engineering applicability and market promotion value. Detailed Implementation

[0020] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] This invention provides a foamed aluminum-gypsum composite partition wall with high sound insulation performance, employing a five-layer symmetrical composite structure: fire-resistant gypsum board, a damping sound-insulating adhesive layer, a gradient-pore open-cell foamed aluminum core layer, another damping sound-insulating adhesive layer, and finally, fire-resistant gypsum board. The gradient-pore open-cell foamed aluminum core layer has a thickness of 40-80mm, a porosity of 80%-90%, a surface pore size of 100-300μm, and an internal pore size of 500-800μm. The damping sound-insulating adhesive layer is a 2-3mm thick butyl damping sound-insulating adhesive. The fire-resistant gypsum board has a thickness of 12-15mm. The foamed aluminum core layer and the fire-resistant gypsum board are bonded together with environmentally friendly polyurethane structural adhesive and fixed by nested C-shaped cold-rolled galvanized light steel keel with a center-to-center spacing of 400-600mm. The partition wall joints utilize a double-sealing process using sealant and grooves.

[0022] The present invention does not impose any special restrictions on the source of the fire-resistant gypsum board, butyl damping sound insulation adhesive, gradient pore size open-cell aluminum foam core layer, environmentally friendly polyurethane structural adhesive, C-type cold-rolled galvanized light steel keel, sealant and PVC card slot. Commercially available brand products known to those skilled in the art or self-made according to the method described in the present invention can be used.

[0023] In this invention, the refractory gypsum board is made from the following raw materials by weight percentage: 3-4 wt% glass fiber, 5-8 wt% expanded perlite, 17-20 wt% aluminum hydroxide / magnesium hydroxide composite inorganic flame retardant, and the remainder being building gypsum. Specifically, the glass fiber is selected from commercially available alkali-free wet-process chopped filament 546 from China Jushi Co., Ltd., with a chopped length of 6 mm, specifically for gypsum reinforcement; the expanded perlite is selected from 10-30 mesh industrial-grade granules from Xinyang Zhongke Mining; the aluminum hydroxide is selected from industrial-grade AH-1 from Chalco Shandong Co., Ltd., with Al(OH)3 ≥ 99.6%; the magnesium hydroxide is selected from industrial-grade MH-10 from Shandong Chenxu New Materials; and the building gypsum is selected from α-type high-strength building gypsum from Shandong Shengquan Group, with a standard consistency water requirement ≤ 65%. The preparation method of fire-resistant gypsum board is as follows: mix thoroughly at 300-500 r / min for 10-15 min according to the formula, press under 5-8 MPa pressure for 1-2 min to form, steam cure at 80-90℃ for 4-6 h, and dry at 100-110℃ until the moisture content is ≤1.5%. In the aluminum hydroxide / magnesium hydroxide composite inorganic flame retardant, the mass ratio of aluminum hydroxide to magnesium hydroxide is 1:4.

[0024] In this invention, the damping resin in the butyl damping sound insulation adhesive is a phenolic modified epoxy damping resin. Specifically, the epoxy resin is Baling Petrochemical bisphenol A type epoxy resin CYD-128; the phenolic resin is Jinan Shengquan 2123 thermoplastic phenolic resin; the methyl hexahydrophthalic anhydride curing agent is Puyang Huicheng MHHPA industrial grade; and the dibutyltin dilaurate catalyst is Evonik T-12 from Germany. The preparation method of the phenolic modified epoxy damping resin is as follows: 100 parts of epoxy resin, 35-45 parts of phenolic resin, 8-12 parts of methyl hexahydrophthalic anhydride curing agent, and 0.5-1 parts of dibutyltin dilaurate catalyst are mixed, stirred at 200-300 r / min, reacted at 120-130℃ for 2-3 h, and cooled to 25±5℃ at 5-10℃ / min to obtain the modified damping resin.

[0025] In this invention, the butyl damping sound insulation adhesive is composed of 30-32 wt% calcium carbonate filler, 15-18 wt% of the above-mentioned modified damping resin, 15-17 wt% antioxidant 264, and the balance butyl rubber. The calcium carbonate filler is selected from Guangxi Guilin Huatuo 1250 mesh light calcium carbonate; the antioxidant 264 is selected from Jiangsu Shengao BHT (2,6-di-tert-butyl-p-cresol) industrial grade; and the butyl rubber is selected from Yanshan Petrochemical IIR1751. The above raw materials are mixed at 100-120℃ for 15-20 min, calendered at 80-100℃ to a thickness tolerance of ±0.1 mm, and then coated at 60-80℃ at a rate of 0.8-1.2 m / min.

[0026] In this invention, the gradient pore size open-cell aluminum foam core layer uses industrial pure aluminum ≥99.5wt% as the matrix and titanium dihydrogenide with a particle size of 200-300 mesh as the foaming agent. The industrial pure aluminum is selected from Al99.70 aluminum ingots from Aluminum Corporation of China; the titanium dihydrogenide foaming agent is industrial grade TiH2 from Xi'an Baotai Special Materials Co., Ltd., with a particle size of 200-300 mesh. It is prepared using a directional melt foaming process: the aluminum melt is heated to 680-720℃, 0.8-1.2wt% titanium dihydrogenide is added, and the mixture is held at a directional pressure of 0.1-0.3MPa for 3-5 minutes. The mixture is then cooled in a mold at a rate of 10-15℃ / min to below 50℃ for molding.

[0027] In this invention, the environmentally friendly polyurethane structural adhesive is a single-component polyurethane structural adhesive with a solid content ≥95%, room temperature moisture curing, and tensile shear strength ≥1.2MPa. 3M™ 560 single-component moisture-curing polyurethane structural adhesive is selected, which meets the requirements of solid content ≥95%, tensile shear strength ≥1.2MPa, and application thickness of 0.2-0.5mm.

[0028] In this invention, the double sealing process involves continuously and fully filling the interior of the joint with FV-0 grade silicone flame-retardant sealant at an application pressure of 0.2-0.3 MPa, using Guangzhou Baiyun SS507 fireproof sealant, which meets the GB / T2408-2008 standard for FV-0 grade. The exterior of the joint is covered with a 1.5mm thick, FV-0 grade, 50mm×15mm U-shaped PVC groove with a clamping pressure of 0.1-0.2 MPa, using a commonly used FV-0 grade flame-retardant U-shaped PVC groove in the domestic building materials market. A 1mm thick, FV-0 grade butyl rubber sound insulation pad is hot-pressed onto the inner wall of the groove, using Hebei Hengchuang FV-0 grade butyl rubber sound insulation pad, and the pad is seamlessly bonded to the wall surface, achieving complete sealing of the joint.

[0029] In this invention, the partition wall is a standardized modular unit, with each module having a planar dimension of 1200mm × 2400mm. The module thickness is consistent with the total thickness of the five-layer symmetrical composite structure. Both the vertical and horizontal joints of the modular units employ a double-sealing process using sealant and slots. The C-type cold-rolled galvanized light steel keel is selected from Beixin Building Materials C75 type light steel keel, with a galvanized layer ≥80g / m². 2 It conforms to GB / T11981-2022.

[0030] The foamed aluminum-gypsum composite partition wall provided by this invention has high sound insulation performance. Through a five-layer symmetrical composite structure, a gradient pore size foamed aluminum core layer, a special damping sound insulation adhesive layer, full bonding with environmentally friendly structural adhesive, nesting of light steel keel, and double sealing process, it achieves an airborne sound insulation of 45-55 dB in the 50-1000 Hz frequency band, and its self-weight per unit area in the dry state is 30-50 kg / m². 2The overall fire resistance rating reaches Class A, and it also has the advantages of stable molding, convenient installation, excellent splicing and sealing effect, and strong durability, solving the problems of poor sound insulation, low fire resistance, unreasonable weight, and sealing failure of traditional partition walls.

[0031] Example 1:

[0032] Preparation of fire-resistant gypsum board: By weight percentage, 3wt% glass fiber, 5wt% expanded perlite, 17wt% aluminum hydroxide / magnesium hydroxide composite inorganic flame retardant, and the remainder of building gypsum are selected as raw materials. The mixture is stirred at 300r / min for 10min to achieve uniform mixing, pressed under 5MPa pressure for 1min to form the board, steam cured at 80℃ for 4h, and dried at 100℃ until the moisture content is ≤1.5%, resulting in a fire-resistant gypsum board with a thickness of 12mm.

[0033] Preparation of phenolic modified epoxy damping resin: 100 parts epoxy resin, 35 parts phenolic resin, 8 parts methyl hexahydrophthalic anhydride curing agent, and 0.5 parts dibutyltin dilaurate catalyst were mixed, stirred at 200 r / min, reacted at 120℃ for 2 h, and cooled to 25±5℃ at 5℃ / min to obtain modified damping resin.

[0034] Preparation of butyl damping sound insulation adhesive: 30wt% calcium carbonate filler, 15wt% modified damping resin, 15wt% antioxidant 264, and the balance butyl rubber were selected by weight percentage. The mixture was mixed at 100℃ for 15min, calendered at 80℃ to a thickness tolerance of ±0.1mm, and then coated at 60℃ at a rate of 0.8m / min to obtain a butyl damping sound insulation adhesive with a thickness of 2mm.

[0035] Preparation of graded pore size open-cell foam aluminum core layer: using industrial pure aluminum ≥99.5wt% as matrix and titanium dihydrogen 200 mesh as foaming agent, the aluminum melt is heated to 680℃, 0.8wt% titanium dihydrogen 200 mesh is added, and the temperature is held for 3 min under directional pressure of 0.1MPa. The foam is then cooled to below 50℃ at a rate of 10℃ / min to form a foam aluminum core layer with a thickness of 40mm, a porosity of 80%, a surface pore size of 100μm, and an internal pore size of 500μm.

[0036] Apply adhesive layer: Apply 2mm butyl damping sound insulation adhesive evenly to the inside of the fire-resistant gypsum board at 60℃ and a speed of 0.8m / min. Apply environmentally friendly polyurethane structural adhesive to the adhesive surface with a thickness of 0.2mm.

[0037] Composite molding: Align and bond the aluminum foam core layer with the plasterboard on both sides, and pressurize at 0.1MPa for 10 minutes at room temperature of 25±5℃ to complete the bonding and molding.

[0038] Keel installation: Install C-type cold-rolled galvanized light steel keel at 400mm intervals, and nest the keel and the aluminum foam core layer at a depth of 5mm. Secure with Φ4.8mm galvanized self-tapping screws at 150mm intervals.

[0039] Double sealing: The inside of the joint is continuously and fully filled with FV-0 grade silicone flame retardant sealant with an application pressure of 0.2MPa. The outside of the joint is covered with a PVC groove with a wall thickness of 1.5mm, FV-0 grade, and a U-shaped cross section of 50mm×15mm with a clamping pressure of 0.1MPa. The inner wall of the groove is hot-pressed to bond a 1mm thick FV-0 grade butyl rubber sound insulation pad and it is seamlessly attached to the surface of the partition wall.

[0040] Curing before shipment: The entire product is left to cure at 25±5℃ for 24 hours, and is shipped after passing the inspection.

[0041] Example 2:

[0042] Preparation of fire-resistant gypsum board: By weight percentage, 4wt% glass fiber, 8wt% expanded perlite, 20wt% aluminum hydroxide / magnesium hydroxide composite inorganic flame retardant, and the remainder of building gypsum are selected as raw materials. The mixture is stirred at 500r / min for 15min to achieve uniform mixing, pressed under 8MPa pressure for 2min to form the board, steam cured at 90℃ for 6h, and dried at 110℃ until the moisture content is ≤1.5%, resulting in a fire-resistant gypsum board with a thickness of 15mm.

[0043] Preparation of phenolic modified epoxy damping resin: 100 parts epoxy resin, 45 parts phenolic resin, 12 parts methyl hexahydrophthalic anhydride curing agent, and 1 part dibutyltin dilaurate catalyst were mixed, stirred at 300 r / min, reacted at 130℃ for 3 h, and cooled to 25±5℃ at 10℃ / min to obtain modified damping resin.

[0044] Preparation of butyl damping sound insulation adhesive: 32wt% calcium carbonate filler, 18wt% modified damping resin, 17wt% antioxidant 264, and the balance butyl rubber were selected by weight percentage. The mixture was mixed at 120℃ for 20min, calendered at 100℃ to a thickness tolerance of ±0.1mm, and coated at 80℃ at a rate of 1.2m / min to obtain a butyl damping sound insulation adhesive with a thickness of 3mm.

[0045] Preparation of gradient pore size open-cell foam aluminum core layer: using industrial pure aluminum ≥99.5wt% as matrix and titanium dihydrogen 300 mesh as foaming agent, the aluminum melt is heated to 720℃, 1.2wt% titanium dihydrogen hydrate is added, and the temperature is held for 5 min under directional pressure of 0.3MPa. The foam is then cooled to below 50℃ at a rate of 15℃ / min to form a foam aluminum core layer with a thickness of 80mm, a porosity of 90%, a surface pore size of 300μm, and an internal pore size of 800μm.

[0046] Apply adhesive layer: Apply 3mm butyl damping sound insulation adhesive evenly to the inside of the fire-resistant gypsum board at 80℃ and a speed of 1.2m / min. Apply environmentally friendly polyurethane structural adhesive to the adhesive surface with a thickness of 0.5mm.

[0047] Composite molding: Align and bond the aluminum foam core layer with the plasterboard on both sides, and pressurize at 0.2MPa for 15 minutes at room temperature of 25±5℃ to complete the bonding and molding.

[0048] Keel installation: Install C-type cold-rolled galvanized light steel keel at 600mm intervals, and nest the keel and the foam aluminum core layer at a depth of 10mm, and fasten with Φ4.8mm galvanized self-tapping screws at 200mm intervals.

[0049] Double sealing: The inside of the joint is continuously and fully filled with FV-0 grade silicone flame retardant sealant with an application pressure of 0.3MPa. The outside of the joint is covered with a 1.5mm thick, FV-0 grade, U-shaped 50mm×15mm PVC groove with a clamping pressure of 0.2MPa. The inner wall of the groove is hot-pressed to bond a 1mm thick, FV-0 grade butyl rubber sound insulation pad and it is seamlessly attached to the surface of the partition wall.

[0050] Curing before shipment: The entire product is left to cure at 25±5℃ for 24 hours, and is shipped after passing the inspection.

[0051] Example 3:

[0052] Preparation of fire-resistant gypsum board: By weight percentage, 3.5 wt% glass fiber, 6.5 wt% expanded perlite, 18.5 wt% aluminum hydroxide / magnesium hydroxide composite inorganic flame retardant, and the balance of building gypsum were selected as raw materials. The mixture was stirred at 400 r / min for 12.5 min to achieve uniform mixing, pressed under 6.5 MPa pressure for 1.5 min to form the board, steam cured at 85℃ for 5 h, and dried at 105℃ until the moisture content was ≤1.5%, resulting in a fire-resistant gypsum board with a thickness of 13.5 mm.

[0053] Preparation of phenolic modified epoxy damping resin: 100 parts epoxy resin, 40 parts phenolic resin, 10 parts methyl hexahydrophthalic anhydride curing agent, and 0.75 parts dibutyltin dilaurate catalyst were mixed, stirred at 250 r / min, reacted at 125℃ for 2.5 h, and cooled to 25±5℃ at 7.5℃ / min to obtain modified damping resin.

[0054] Preparation of butyl damping sound insulation adhesive: 31wt% calcium carbonate filler, 16.5wt% modified damping resin, 16wt% antioxidant 264, and the balance butyl rubber were selected by weight percentage. The mixture was mixed at 110℃ for 17.5min, calendered at 90℃ to a thickness tolerance of ±0.1mm, and then coated at 70℃ at a rate of 1.0m / min to obtain a butyl damping sound insulation adhesive with a thickness of 2.5mm.

[0055] Preparation of gradient pore size open-cell foam aluminum core layer: using industrial pure aluminum ≥99.5wt% as matrix and titanium dihydrogen 250 mesh as foaming agent, the aluminum melt is heated to 700℃, 1.0wt% titanium dihydrogen 1 is added, and the temperature is held for 4 min under directional pressure of 0.2MPa. The foam is then cooled to below 50℃ at a rate of 12℃ / min to form a foam aluminum core layer with a thickness of 60mm, a porosity of 85%, a surface pore size of 200μm, and an internal pore size of 650μm.

[0056] Apply adhesive layer: Apply 2.5mm butyl damping sound insulation adhesive evenly to the inside of the fire-resistant gypsum board at 70℃ and a speed of 1.0m / min, and then apply environmentally friendly polyurethane structural adhesive to the adhesive surface with a thickness of 0.35mm.

[0057] Composite molding: Align and bond the aluminum foam core layer with the plasterboard on both sides, and pressurize at 0.15MPa for 12.5 minutes at room temperature of 25±5℃ to complete the bonding and molding.

[0058] Keel installation: Install C-type cold-rolled galvanized light steel keel at 500mm intervals, and nest the keel and the foam aluminum core layer at a depth of 7.5mm. Secure with Φ4.8mm galvanized self-tapping screws at 175mm intervals.

[0059] Double sealing: The inside of the joint is continuously and fully filled with FV-0 grade silicone flame retardant sealant with an application pressure of 0.25MPa. The outside of the joint is covered with a 1.5mm thick, FV-0 grade, U-shaped 50mm×15mm PVC groove with a clamping pressure of 0.15MPa. The inner wall of the groove is hot-pressed to bond a 1mm thick, FV-0 grade butyl rubber sound insulation pad and it is seamlessly attached to the surface of the partition wall.

[0060] Curing before shipment: The entire product is left to cure at 25±5℃ for 24 hours, and is shipped after passing the inspection.

[0061] Comparative Example 1: Compared with Example 3, the gradient pore size open-cell aluminum foam core layer is removed and replaced with a solid gypsum board with a single thickness of 60mm. The rest of the structure, raw materials and process parameters are exactly the same as those in Example 3.

[0062] Comparative Example 2: Compared with Example 3, the butyl damping sound insulation adhesive layer is omitted, and the fire-resistant gypsum board and the foamed aluminum core layer are directly bonded together only by environmentally friendly polyurethane structural adhesive. The rest of the structure, raw materials, and process parameters are exactly the same as in Example 3.

[0063] Comparative Example 3: Compared with Example 3, the fire-resistant gypsum board does not contain aluminum hydroxide / magnesium hydroxide composite inorganic flame retardant, while the remaining raw material ratios, structures, and process parameters are exactly the same as in Example 3.

[0064] Comparative Example 4: Compared with Example 3, the partition wall joint does not use a double sealing process of sealant and groove, but only a simple splicing process. The rest of the structure, raw materials and process parameters are exactly the same as those in Example 3.

[0065] test: Experiment 1: Airborne sound insulation test Test method: In accordance with relevant building sound insulation standards, a sound insulation chamber testing system was used. The test sample was a complete partition wall module of 1200mm×2400mm. The airborne sound insulation in the 50-1000Hz frequency band was tested. Each sample was tested 3 times and the average value was taken.

[0066] Experimental data: Table 150-1000Hz Airborne Sound Insulation

[0067] The sound insulation of Examples 1-3 is in the range of 45-55 dB, which meets the requirements for high sound insulation. Comparative Example 1 has no foamed aluminum core layer, and there is no gradient pore size dissipation path for sound waves, resulting in a significant decrease in sound insulation; Comparative Example 2 has no damping sound insulation adhesive layer, and the structural sound transmission is obvious, weakening the sound insulation effect; Comparative Example 4 has no double seal, and the splicing seam forms a sound bridge, significantly reducing the sound insulation; Comparative Example 3 has no composite flame retardant, and has no significant impact on the sound insulation performance.

[0068] Experiment 2: Weight per unit area in dry state: Test method: The partition wall module to be tested was dried in an oven at 105℃ until constant weight. After cooling to room temperature, the total mass was weighed and divided by the module's planar area of ​​1200mm×2400mm to obtain the self-weight per unit area. Each sample was tested 3 times and the average value was taken.

[0069] Experimental data: Table 2. Weight per unit area in dry state

[0070] The unit area weight of Examples 1-3 is 30-50 kg / m² 2 The weight is reasonable and easy to install. Comparative Example 1 uses solid gypsum board, which has a high density and exceeds the weight limit; Comparative Examples 2, 3, and 4, since the core structure and density were not changed, have a weight close to that of Example 3, with no significant difference.

[0071] Test 3: Fire resistance rating test Test method: The fire resistance performance testing method for building materials was used to conduct fire resistance tests on complete partition wall modules, and the fire resistance rating was determined based on the combustion performance and fire resistance time.

[0072] Experimental data: Table 3 Fire Resistance Rating

[0073] Examples 1-3 achieved an overall fire rating of Class A, demonstrating excellent fire resistance. Comparative Example 3, due to the absence of a composite inorganic flame retardant in the fire-resistant gypsum board, suffered a loss of flame retardant performance, resulting in a fire rating drop to Class B1. Comparative Examples 1, 2, and 4, without altering the core flame-retardant components, maintained their Class A fire resistance.

[0074] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A foamed aluminum-gypsum composite partition wall having high sound insulation performance, characterized by, The system employs a five-layer symmetrical composite structure: fire-resistant gypsum board, a damping and sound-insulating adhesive layer, a gradient-pore-sized open-cell aluminum foam core layer, and another fire-resistant gypsum board. The gradient-pore-sized open-cell aluminum foam core layer has a thickness of 40-80mm, a porosity of 80%-90%, a surface pore size of 100-300μm, and an internal pore size of 500-800μm. The damping and sound-insulating adhesive layer is a 2-3mm thick butyl damping and sound-insulating adhesive. The fire-resistant gypsum board has a thickness of 12-15mm. The aluminum foam core layer and the fire-resistant gypsum board are bonded together with environmentally friendly polyurethane structural adhesive and fixed by nested C-shaped cold-rolled galvanized light steel keel with a center-to-center spacing of 400-600mm. The joints of the partition walls utilize a double-sealing process using sealant and grooves.

2. The composite partition of claim 1, wherein, The fire-resistant gypsum board is made from the following raw materials by weight percentage: 3-4 wt% glass fiber, 5-8 wt% expanded perlite, 17-20 wt% aluminum hydroxide / magnesium hydroxide composite inorganic flame retardant, and the remainder being building gypsum. The preparation method is as follows: mix the materials at 300-500 r / min for 10-15 min until uniform, press them under 5-8 MPa pressure for 1-2 min to form, steam cure at 80-90℃ for 4-6 h, and dry at 100-110℃ until the moisture content is ≤1.5%.

3. The composite partition of claim 2, wherein, In the aluminum hydroxide / magnesium hydroxide composite inorganic flame retardant, the mass ratio of aluminum hydroxide to magnesium hydroxide is 1:

4.

4. The composite wall of claim 1, wherein The damping resin in the butyl damping sound insulation adhesive is a phenolic modified epoxy damping resin, which is prepared by mixing 100 parts of epoxy resin, 35-45 parts of phenolic resin, 8-12 parts of methyl hexahydrophthalic anhydride curing agent, and 0.5-1 parts of dibutyltin dilaurate catalyst, stirring at 200-300 r / min, reacting at 120-130℃ for 2-3 h, and cooling at 5-10℃ / min to 25±5℃ to obtain the modified damping resin.

5. The composite wall of claim 4, wherein, The butyl damping sound insulation adhesive is composed of 30-32wt% calcium carbonate filler, 15-18wt% of the above-mentioned modified damping resin, 15-17wt% antioxidant 264, and the balance butyl rubber. It is formed by mixing at 100-120℃ for 15-20min, calendering at 80-100℃ to a thickness tolerance of ±0.1mm, and coating at 60-80℃ at a rate of 0.8-1.2m / min.

6. The composite wall of claim 1, wherein The gradient pore size open-cell foam aluminum core layer is prepared using industrial pure aluminum ≥99.5wt% as the matrix and titanium dihydrogenide with a particle size of 200-300 mesh as the foaming agent, and adopts a directional melt foaming process: the aluminum melt is heated to 680-720℃, 0.8-1.2wt% titanium dihydrogenide is added, the temperature is held for 3-5 minutes under a directional pressure of 0.1-0.3MPa, and the mold is cooled to below 50℃ at a rate of 10-15℃ / min to form the core.

7. The composite partition wall according to claim 1, characterized in that, The environmentally friendly polyurethane structural adhesive is a single-component polyurethane structural adhesive with a solid content ≥95%, room temperature moisture curing, and tensile shear strength ≥1.2MPa, with an application thickness of 0.2-0.5mm.

8. The composite partition wall according to claim 1, characterized in that, The dual sealing process is as follows: the inside of the splice joint is continuously and fully filled with FV-0 grade silicone flame retardant sealant with an application pressure of 0.2-0.3MPa; the outside of the splice joint is covered with a PVC groove with a wall thickness of 1.5mm, FV-0 grade, and a U-shaped cross section of 50mm×15mm with a clamping pressure of 0.1-0.2MPa; a 1mm thick FV-0 grade butyl rubber sound insulation pad is hot-pressed onto the inner wall of the groove and fits seamlessly with the surface of the partition wall, thus achieving full sealing of the splice joint.

9. The composite partition wall according to claim 1, characterized in that, The partition wall is a standardized modular unit, with a single module having a planar dimension of 1200mm × 2400mm. The module thickness is consistent with the total thickness of the five-layer symmetrical composite structure. The vertical and horizontal splicing seams of the modular units are sealed using a double sealing process of sealant and slot.

10. The composite partition wall according to claim 1, characterized in that, The method for preparing the composite partition wall is as follows: (1) Prepare refractory gypsum board, butyl damping sound insulation adhesive, and gradient pore size foam aluminum core layer according to the method described above; (2) Apply 2-3 mm butyl damping sound insulation adhesive evenly to the inside of the refractory gypsum board at 60-80℃ and a speed of 0.8-1.2 m / min; (3) Apply the environmentally friendly polyurethane structural adhesive to the adhesive-coated surface of the refractory gypsum board, with an adhesive thickness of 0.2-0.5 mm; (4) Align and bond the aluminum foam core layer with the plasterboard on both sides, and pressurize at 0.1-0.2MPa for 10-15 minutes at room temperature of 25±5℃ to complete the bonding and molding; (5) Install C-type cold-rolled galvanized light steel keel at a spacing of 400-600mm, and nest the keel and the foam aluminum core layer at a depth of 5-10mm, and fasten with Φ4.8mm galvanized self-tapping screws at a spacing of 150-200mm; (6) Fill the joint of the partition wall with FV-0 grade silicone flame retardant sealant and wrap the U-shaped PVC groove with a clamping pressure of 0.1-0.2MPa to complete the double seal; (7) The whole thing is left to stand at 25±5℃ for 24 hours to cure. After the sound insulation and fire resistance are tested and found to be qualified, it is ready to leave the factory.

Images