A method of manufacturing water-activated micro-expanding dry powder tiling acoustic tiles

Abstract

A method for manufacturing sound-insulating ceramic tiles using water-activated micro-expansion dry powder includes the following steps: assembling a honeycomb upper skin layer and a honeycomb core layer; filling the pores of the honeycomb core layer with micro-expansion dry powder and compacting it with vibration; spraying a water-soluble polyvinyl alcohol solution onto the surface of the filled dry powder, drying it with hot air to form a water-soluble polyvinyl alcohol film, and then attaching a protective layer; and finally, attaching the surface layer to the upper surface of the honeycomb core module using an adhesive layer to obtain the finished product. This invention enables factory prefabrication, dry quick installation, no mortar mixing, self-leveling upon contact with water, adaptive performance with 3-5mm height differences, and micro-expansion compaction without hollow areas. Simultaneously, through the synergistic effect of the honeycomb structure and flexible layer, it meets the mandatory requirement of GB 55038-2025 for floor impact sound insulation ≤65dB.

Description

Technical Field

[0001] This invention belongs to the field of prefabricated building materials technology, specifically relating to a manufacturing method for water-activated micro-expansion dry powder for laying sound-insulating ceramic tiles. Background Technology

[0002] Currently, most building interior floors are paved with ceramic tiles or sintered stone, which offer advantages such as waterproofing, high strength, impact resistance, and deformation resistance. However, the installation of large-format ceramic tiles still relies on traditional on-site mixing of cement mortar for paving, leveling, and filling, presenting a significant technical bottleneck. 1. Wet work involves complicated procedures, high reliance on manual labor, and low construction efficiency. Laying large-format tiles requires extremely high skill from workers and is prone to problems such as hollowing, cracking, warping, and poor flatness. 2. Traditional cement mortar has high density and high shrinkage rate, which is not compatible with the mechanical properties of honeycomb panels, and is prone to delamination, debonding, and surface cracking; 3. Existing cement blankets, expanding mortar, and self-leveling materials are all independent bulk materials. The on-site mortar mix ratio is unstable and the quality consistency is poor, which cannot meet the standardized, branded, and industrialized delivery needs of tile companies. 4. It cannot adapt to ground height differences of 3~5mm, pits, and gaps, requiring an additional leveling layer, which involves more procedures, longer cycles, and higher overall costs; 5. Large-format ceramic tiles laid with traditional cement mortar have poor sound insulation, and sound insulation mainly relies on the sound insulation effect of the floor slab itself. Summary of the Invention

[0003] To address the problems of existing large-format tile installation methods, such as reliance on on-site cement mortar, high labor costs, low construction efficiency, unstable quality, inability to adapt to ground elevation differences, and failure to meet sound insulation requirements, this invention provides a prefabricated lightweight composite tile modular flooring construction method. This method achieves factory prefabrication, dry and rapid installation, no mortar mixing, self-leveling upon contact with water, adaptability to 3-5mm elevation differences, and micro-expansion to achieve dense and non-hollow surfaces. Simultaneously, through the synergistic effect of the honeycomb structure and flexible layer, it meets the mandatory requirement of GB 55038-2025 for impact sound insulation of floor slabs ≤65dB.

[0004] The present invention is implemented as follows: A method for manufacturing a water-activated micro-expansion dry powder for laying sound-insulating ceramic tiles, wherein the ceramic tile has a composite multi-layer structure, comprising, from top to bottom: a surface layer, an adhesive layer, a honeycomb upper skin layer, a honeycomb core layer, a water-soluble encapsulation layer, and a protective layer; the honeycomb core layer is quantitatively filled with dry micro-expansion dry powder.

[0005] The water-soluble encapsulation layer is made of water-soluble polyvinyl alcohol (PVA). Water-soluble PVA possesses properties such as acid and alkali resistance, and controllable water solubility; its aqueous solution is biodegradable and pollution-free. Upon contact with water, the water-soluble encapsulation layer dissolves, releasing dry powder from the honeycomb cells. The dry powder combines with water to form a micro-expansion mortar. A PVA solution is sprayed onto the honeycomb cells and dried with hot air to form a PVA film, preventing the micro-expansion dry powder from overflowing.

[0006] Its manufacturing methods include: (1) Combine the honeycomb upper skin layer and honeycomb core layer, fill the pores of the honeycomb core layer with micro-expanded dry powder, and vibrate to compact it; (2) Spray a water-soluble polyvinyl alcohol solution onto the surface of the filled dry powder, dry it with hot air to form a water-soluble polyvinyl alcohol film, and then paste a protective layer. (3) The surface layer is bonded to the upper surface of the honeycomb core module through an adhesive layer to obtain the finished product.

[0007] The micro-expanding dry powder is composed of the following components by weight: 80-120 parts silicate cement, 5-10 parts calcium oxide, 80-120 parts quartz sand, 0.1-1 parts polycarboxylate superplasticizer, 1.5-5 parts redispersible latex powder, 0.1-1 parts basalt chopped fibers, and 0.1-1 parts hydroxypropyl methylcellulose. The linear expansion rate of the micro-expanding dry powder is controlled at 0.2%, the dry density is ≤1100 kg / m³, the flowability is 160-180 mm, and the 24-hour compressive strength is ≥15 MPa.

[0008] Silicate cement (PO 42.5), the main cementing material, provides strength; calcium oxide (quicklime powder, 200 mesh, activity ≥90%), is a source of plastic expansion, enabling self-leveling; quartz sand (40-70 mesh), aggregate, regulates fluidity and volume stability; hydroxypropyl methylcellulose (HPMC, viscosity 400), retains water and thickens, improving workability; redispersible latex powder enhances bonding flexibility and improves crack resistance; polycarboxylate superplasticizer (powder) improves fluidity and reduces the water-cement ratio; basalt chopped fibers (6mm in length) enhance crack resistance and improve durability.

[0009] The water-soluble polyvinyl alcohol solution is prepared by taking 10%~12% by weight of water-soluble polyvinyl alcohol dry powder, 0.2% of defoamer, and the remainder of water, mixing and heating to 90°C to dissolve, and then cooling to 45°C to obtain the solution.

[0010] The surface layer is made of porcelain brick, rock slab, or thin ceramic slab.

[0011] The flexible bonding transition layer is a flexible epoxy resin, polyurethane adhesive, or flexible tile adhesive.

[0012] The protective layer is coated kraft paper.

[0013] The construction method for applying water-activated micro-expansion dry powder to sound-insulating ceramic tiles includes the following steps: S1. Factory prefabrication: The surface layer, adhesive layer, honeycomb upper skin layer, honeycomb core layer, water-soluble encapsulation layer and protective layer are combined and encapsulated to form standardized modules; S2. On-site dry laying: Clean the base layer, peel off the protective layer, spray water evenly onto the water-soluble encapsulation layer at the bottom of the module, or pour water on the ground to be laid, and then lay the bottom of the module directly on the ground; S3. Water-activated leveling: The water-soluble encapsulation layer dissolves when it comes into contact with water. The water penetrates into the dry powder, causing it to wet, flow, and expand. The resulting mortar expands and protrudes below the honeycomb holes, contacting the ground to achieve adaptive leveling with a 3-5mm ground height difference. At the same time, the resulting mortar fills the pits, gaps, and honeycomb cavities in the base layer. S4. Curing and Shaping: Natural curing at room temperature, the dry powder hydrates and hardens to form an integral rigid support layer, and the module is tightly bonded to the base layer to complete the installation.

[0014] The beneficial effects of this invention are: 1. This invention changes the traditional wet paving process that involves "on-site mixing and leveling". The pre-installed components are completed in the factory, and the integrated composite modules are directly transported to the paving site, greatly simplifying the on-site construction method. Only two steps are required: "sprinkling water and paving", which can improve paving and installation efficiency by 300%.

[0015] 2. The dry powder in this invention has the characteristic of micro-expansion. After controlled hydration, the micro-expansion mortar comes into contact with the ground and produces a self-leveling effect, which can eliminate a 3-5mm ground height difference and completely eliminate the problem of hollow spots in thin-layer paving.

[0016] 3. This invention features a honeycomb panel sound insulation structure with built-in sound insulation. Through the flexible support of the fiberglass PP honeycomb core layer, the 1-2mm air sound insulation layer formed within the honeycomb cells, and the synergistic effect of the flexible bonding transition layer, third-party testing shows that the impact sound insulation L,w=62dB, which is far below the mandatory standard of ≤65dB specified in GB 55038-2025. This effectively solves the problem of floor noise transmission and meets national mandatory compliance requirements.

[0017] 4. The present invention significantly reduces the difficulty of the construction and paving process, lowers the skill requirements for construction workers, reduces labor intensity by 70%, eliminates reliance on skilled tile setters, ensures high quality consistency, and is suitable for large-scale fine decoration and old house renovation; the overall labor cost is reduced by 150% compared with the traditional dry paving method.

[0018] 5. The ground module of this invention is lightweight, high-strength, crack-resistant, and deformation-resistant. Its density is reduced by more than 50% compared with traditional mortar, which reduces the building load and improves the safety and durability of the product. Attached Figure Description

[0019] Figure 1 This is an exploded view of each layer of the composite ground module of the present invention; Figure 2 This is a schematic cross-sectional view of the composite flooring module of the present invention; (completed on-site installation state). Figure 3 This is a flowchart of the manufacturing process of the present invention; The numbers and component names in the diagram are as follows: 1—Surface layer; 2—Adhesive layer; 3—Honeycomb upper skin layer; 4—Honeycomb core layer; 5—Water-soluble encapsulation layer; 6—Micro-expanded dry powder; 7—Protective layer. Detailed Implementation

[0020] Example 1

[0021] A method for manufacturing a water-activated micro-expansion dry powder for laying sound-insulating ceramic tiles, wherein the ceramic tile has a composite multi-layer structure, comprising, from top to bottom: a surface layer 1, an adhesive layer 2, a honeycomb upper skin layer 3, a honeycomb core layer 4, a water-soluble encapsulation layer 5, and a protective layer 7; the honeycomb core layer 4 is quantitatively filled with dry micro-expansion dry powder 6; the water-soluble encapsulation layer 5 is prepared from water-soluble polyvinyl alcohol.

[0022] Its manufacturing methods include: S1. Combine the honeycomb upper skin layer 3 and honeycomb core layer 4, fill the pores of the honeycomb core layer 4 with micro-expanded dry powder 6, and vibrate to compact it; S2. Spray a water-soluble polyvinyl alcohol solution onto the surface of the filled dry powder, dry it with hot air to form a water-soluble polyvinyl alcohol film, and then attach the protective layer 7. S3. Adhere the surface layer 1 to the upper surface of the honeycomb core module through the adhesive layer 2 to obtain the finished product.

[0023] The micro-expanded dry powder is composed of the following parts by weight: 100 parts silicate cement, 6 parts calcium oxide, 100 parts quartz sand, 0.4 parts polycarboxylate superplasticizer, 3 parts redispersible latex powder, 0.6 parts basalt chopped fibers, and 0.3 parts hydroxypropyl methylcellulose.

[0024] The linear expansion rate of the micro-expanded dry powder is controlled at 0.2%, the dry density is ≤1100kg / m³, the flowability is 160~180mm, and the 24h compressive strength is ≥15MPa.

[0025] The water-soluble polyvinyl alcohol solution is prepared by taking 11% by weight of water-soluble polyvinyl alcohol dry powder, 0.2% of defoamer, and the remainder of water, mixing and heating to 90°C to dissolve, and then cooling to 45°C to obtain the solution.

[0026] The surface layer 1 is a porcelain tile, rock slab, or ceramic slab.

[0027] The adhesive layer 2 is a flexible epoxy resin, polyurethane adhesive, or flexible tile adhesive.

[0028] The protective layer 7 is coated kraft paper.

[0029] P1 type: room temperature fast-dissolving type, water-soluble polyvinyl alcohol dissolves in water at room temperature (20℃±5℃) in ≤10 seconds.

[0030] Compared with traditional dry powder mortar, the performance indicators of this invention are: 1. With a plastic expansion rate of 0.18%, compared to 0.02% for traditional dry powder mortar, it can automatically fill unevenness in the base layer and achieve self-leveling.

[0031] 2. The hollow rate is 0.5%, which is 76% lower than the 2.1% of traditional dry powder mortar; 3. The 24-hour compressive strength is 9.5 MPa, which is 11.8% higher than the 8.5 MPa of traditional dry-mix mortar; 4. The construction efficiency is 95㎡ / person•day, which is more than 3 times higher than the 30㎡ / person•day of traditional dry powder mortar; 5. Sound insulation performance is 61.3 dB, which is better than the national standard ≤65 dB.

[0032] After activation by spraying water on site, it can adapt to height differences of 3~5mm. People can stand on it after 24 hours, and it is fully cured in 72 hours without hollow areas or cracks. According to third-party testing by SGS, the impact sound insulation is 62dB, which meets the mandatory requirements of GB 55038-2025.

[0033] Example 2

[0034] The remaining steps are the same. The method for preparing the water-soluble polyvinyl alcohol solution is as follows: take 12% by weight of water-soluble polyvinyl alcohol dry powder, 0.2% of defoamer, and the remainder is water, and mix them to obtain the solution.

[0035] P2 type was obtained: medium temperature activated type, which dissolves in warm water at 40℃-90℃ for ≤30 seconds and remains intact after being placed in an environment at 40℃ and 90% humidity for 72 hours.

[0036] Example 3

[0037] Effect of calcium oxide content on performance Based on Example 1, the amount of calcium oxide added was changed:

[0038] Example 4 Effect of Quartz Sand Content on Performance Based on Example 1, the amount of quartz sand was changed:

[0039] Conclusion: When the content of quartz sand is 80-120 parts, the fluidity, strength and uniformity are optimal.

[0040] Example 5

[0041] Effect of basalt fiber content on performance Based on Example 1, the amount of basalt short-cut fiber content was changed:

[0042] Conclusion: When the fiber content is 0.5-1.0 parts, the strength and crack resistance are significantly improved.

Claims

1. A method for manufacturing a water-activated micro-expansion dry powder for laying sound-insulating ceramic tiles, characterized in that: The ceramic tile has a composite multi-layer structure, comprising, from top to bottom, a surface layer (1), an adhesive layer (2), a honeycomb upper skin layer (3), a honeycomb core layer (4), a water-soluble encapsulation layer (5), and a protective layer (7); the honeycomb core layer (4) is quantitatively filled with dried, micro-expanded dry powder (6); the water-soluble encapsulation layer (5) is prepared from water-soluble polyvinyl alcohol. Its manufacturing method includes: S1. Combine the honeycomb upper skin layer (3) and honeycomb core layer (4), fill the pores of the honeycomb core layer (4) with micro-expanded dry powder (6), and vibrate to compact it; S2. Spray a water-soluble polyvinyl alcohol solution onto the surface of the filled dry powder, dry it with hot air to form a water-soluble polyvinyl alcohol film, and then attach a protective layer (7). S3. The surface layer (1) is bonded to the upper surface of the honeycomb core module through the adhesive layer (2) to obtain the finished product.

2. The manufacturing method of the water-activated micro-expansion dry powder for laying sound-insulating ceramic tiles according to claim 1, characterized in that: The micro-expanded dry powder is composed of the following components by mass: 80-120 parts silicate cement, 5-10 parts calcium oxide, 80-120 parts quartz sand, 0.1-1 parts polycarboxylate superplasticizer, 1.5-5 parts redispersible latex powder, 0.1-1 parts basalt chopped fiber, and 0.1-1 parts hydroxypropyl methylcellulose.

3. The manufacturing method of the water-activated micro-expansion dry powder for laying sound-insulating ceramic tiles according to claim 1, characterized in that: The linear expansion rate of the micro-expanded dry powder is controlled at 0.2%, the dry density is ≤1100kg / m³, the flowability is 160~180mm, and the 24h compressive strength is ≥15MPa.

4. The manufacturing method of the water-activated micro-expansion dry powder for laying sound-insulating ceramic tiles according to claim 1, characterized in that: The water-soluble polyvinyl alcohol solution is prepared by taking 10%~12% by weight of water-soluble polyvinyl alcohol dry powder, 0.2% of defoamer, and the remainder of water, mixing and heating to 90°C to dissolve, and then cooling to 45°C to obtain the solution.

5. The manufacturing method of the water-activated micro-expansion dry powder for laying sound-insulating ceramic tiles according to claim 1, characterized in that: The surface layer (1) is a porcelain tile, rock slab or ceramic slab.

6. The manufacturing method of the water-activated micro-expansion dry powder for laying sound-insulating ceramic tiles according to claim 1, characterized in that, The adhesive layer (2) is a flexible epoxy resin, polyurethane adhesive or flexible tile adhesive.

7. The manufacturing method of the water-activated micro-expansion dry powder for laying sound-insulating ceramic tiles according to claim 1, characterized in that, The protective layer (7) is coated kraft paper.

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