Phenolic foam sound insulation board

Abstract

The utility model relates to the technical field of sound insulation plates, in particular to a phenolic foam sound insulation plate. The structure sequentially comprises a surface sound absorption layer, a first enhancement layer, a main sound insulation layer, a second enhancement layer, a fireproof layer and a bottom reflection layer from top to bottom. The surface sound-absorbing layer is made of open-cell phenolic foam, and a hemispherical groove is formed in the surface of the surface sound-absorbing layer; the main sound insulation layer is made of closed-cell phenolic foam; the first reinforcing layer and the second reinforcing layer are made of glass fiber gridding cloth and are embedded into the upper surface and the lower surface of the main sound insulation layer respectively. The fireproof layer adopts a nano aluminum hydroxide coating and is coated on one side, far away from the main sound insulation layer, of the second enhancement layer; the bottom reflecting layer is an aluminum foil film and covers the side, away from the main sound insulation layer, of the fireproof layer. Through the design of a multi-layer composite structure, the sound insulation performance and the strength and fireproof performance of the sound insulation board are effectively improved, multiple noise reduction mechanisms of sound absorption, blocking and reflection are formed, and the sound insulation board can be widely applied to building and industrial scenes and has environment friendliness and economical efficiency.

Description

Technical Field

[0001] This utility model relates to the field of sound insulation materials technology, and in particular to a phenolic foam sound insulation board. Background Technology

[0002] With the increasing demand for sound insulation materials in the construction and industrial sectors, the application of traditional sound insulation materials such as rock wool, glass wool, and polyurethane foam has gradually revealed significant shortcomings. While these materials meet basic sound insulation requirements to some extent, their absorption of low-frequency noise is generally poor, making it difficult to cope with the diverse noise interference in complex acoustic environments. Furthermore, the flammable nature of some materials makes it difficult to meet fire resistance standards. For example, polyurethane foam easily releases toxic gases when burning, posing a safety hazard and limiting its use in scenarios with strict fire protection requirements. Long-term stability issues have also become a bottleneck for traditional materials. Some sound insulation materials are highly hygroscopic and easily affected by environmental humidity, leading to aging or performance degradation, resulting in a significant decrease in sound insulation effectiveness over time. In terms of environmental friendliness, some materials may release harmful substances during production or use, not only burdening the environment but also posing potential threats to human health.

[0003] In recent years, phenolic foam has attracted attention due to its excellent flame retardancy and low smoke toxicity. However, existing technologies that directly use phenolic foam boards still have significant shortcomings. A single phenolic foam layer structure is insufficient for efficient absorption of noise across a wide frequency range, and its low mechanical strength and inadequate compressive and bending resistance make it prone to deformation or damage under complex working conditions. Furthermore, the structural design of existing products lacks targeted optimization for sound wave reflection and scattering, further limiting the potential for improving sound insulation performance.

[0004] To address the aforementioned issues, those skilled in the art urgently need a novel composite sound insulation material that combines high sound insulation performance, excellent fire resistance, stable mechanical strength, and environmental friendliness to meet current practical application needs. Utility Model Content

[0005] To overcome the shortcomings of the existing technology, this utility model provides a phenolic foam sound insulation board, which, from top to bottom, includes a surface sound-absorbing layer, a first reinforcing layer, a main sound insulation layer, a second reinforcing layer, a fireproof layer, and a bottom reflective layer.

[0006] The surface sound-absorbing layer is made of open-cell phenolic foam, and its surface is provided with hemispherical grooves.

[0007] The main sound insulation layer is made of closed-cell phenolic foam;

[0008] The first and second reinforcing layers are made of fiberglass mesh and are embedded in the upper and lower surfaces of the main sound insulation layer, respectively.

[0009] The fireproof layer is made of nano-aluminum hydroxide coating and is applied to the side of the second reinforcing layer away from the main sound insulation layer.

[0010] The bottom reflective layer is made of aluminum foil and covers the side of the fireproof layer away from the main sound insulation layer.

[0011] Based on the above scheme, the hemispherical grooves are further distributed regularly on the surface of the surface sound-absorbing layer, with a diameter of 4-6mm and a depth of 2-3mm.

[0012] Based on the above scheme, furthermore, ceramic microspheres are dispersed inside the main sound insulation layer.

[0013] Based on the above scheme, the volume of the ceramic microspheres accounts for 5%-8% of the volume of the main sound insulation layer.

[0014] Based on the above scheme, the ceramic microspheres have a particle size of 0.5-2mm.

[0015] Based on the above scheme, the density of the closed-cell phenolic foam is further specified as 60-80 kg / m³. 3 Thermal conductivity ≤0.025W / (m·K).

[0016] Based on the above scheme, furthermore, the surfaces of the first and second reinforcing layers away from the main sound insulation layer are coated with modified epoxy resin.

[0017] Based on the above scheme, the thickness of the surface sound-absorbing layer is 3-5mm; the thickness of the main sound insulation layer is 15-25mm; and the thickness of the bottom reflective layer is 0.1-0.3mm.

[0018] Based on the above solution, the outer periphery of the phenolic foam sound insulation board is further provided with an edge connection structure; the edge connection structure includes protrusions and recesses that can wedge into each other.

[0019] Based on the above scheme, furthermore, the cross-sections of the convex and concave parts are one of trapezoidal, rectangular, triangular and stepped structures.

[0020] Compared with existing technologies, the phenolic foam sound insulation board provided by this utility model effectively improves sound insulation performance, board strength, and fire resistance through a multi-layer composite structure design. The open-cell phenolic foam in the surface sound-absorbing layer, combined with hemispherical grooves, enhances sound wave scattering and absorption efficiency, especially for mid-to-high frequency noise, forming multi-level attenuation. The closed-cell phenolic foam in the main sound insulation layer significantly suppresses low-frequency noise penetration, while the double-layer embedding of fiberglass mesh greatly improves the board's compressive and bending strength, ensuring structural stability during long-term use. The nano-aluminum hydroxide coating in the fireproof layer gives the sound insulation board excellent flame retardant and smoke-suppressing properties, meeting high fire protection standards. The bottom aluminum foil reflective layer further blocks the noise transmission path through sound wave reflection, forming a multi-layer noise reduction mechanism of "sound absorption-blocking-reflection". In addition, the composite of each functional layer takes into account both lightweight and durability, and can be widely used in building and industrial scenarios, combining environmental protection and economy. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 A cross-sectional structural diagram of the phenolic foam sound insulation board provided by this utility model;

[0023] Figure 2 A top view of the phenolic foam sound insulation board provided by this utility model;

[0024] Figure 3 A schematic diagram of the edge connection structure of the phenolic foam sound insulation board provided by this utility model.

[0025] Figure label:

[0026] 10 - Surface sound-absorbing layer; 11 - Hemispherical groove;

[0027] 20 - First reinforcing layer; 30 - Main sound insulation layer; 31 - Ceramic microspheres;

[0028] 40 - Second reinforcing layer; 50 - Fireproof layer; 60 - Bottom reflective layer;

[0029] 70 - Edge connection structure; 71 - Protrusion; 72 - Recess. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0031] In the description of this utility model, it should be noted that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this utility model and simplifying the description. They do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this utility model. In addition, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0032] To provide a novel composite sound insulation material that combines high sound insulation performance, excellent fire resistance, stable mechanical strength, and environmental protection characteristics, this utility model provides a phenolic foam sound insulation board.

[0033] like Figure 1-3 As shown, the phenolic foam sound insulation board includes, from top to bottom, a surface sound-absorbing layer 10, a first reinforcing layer 20, a main sound insulation layer 30, a second reinforcing layer 40, a fireproof layer 50, and a bottom reflective layer 60.

[0034] The surface sound-absorbing layer 10 is made of open-cell phenolic foam, and its surface is provided with hemispherical grooves 11.

[0035] The main sound insulation layer 30 is made of closed-cell phenolic foam;

[0036] The first reinforcing layer 20 and the second reinforcing layer 40 are made of fiberglass mesh and are respectively embedded in the upper and lower surfaces of the main sound insulation layer 30;

[0037] The fireproof layer 50 is made of nano aluminum hydroxide coating and is applied to the side of the second reinforcing layer 40 away from the main sound insulation layer 30;

[0038] The bottom reflective layer 60 is made of aluminum foil and covers the side of the fireproof layer 50 away from the main sound insulation layer 30.

[0039] like Figure 1As shown, by adopting a composite layer structure and optimized material design, it synergistically achieves wide-band noise reduction, high-strength support, and efficient fire resistance, while also being environmentally friendly and economical, and is suitable for diverse sound insulation scenarios such as building walls and industrial equipment.

[0040] Specifically, the surface sound-absorbing layer 10 uses existing open-cell phenolic foam, and its surface is provided with hemispherical grooves 11. The hemispherical grooves 11 form a sound wave scattering surface, expand the sound wave contact area, and, together with the open-cell phenolic foam, enhance the absorption efficiency of mid-to-high frequency noise.

[0041] The first reinforcing layer 20 and the second reinforcing layer 40 are made of fiberglass mesh, which are embedded in the upper and lower surfaces of the main sound insulation layer 30, respectively. The double-layer embedding of fiberglass mesh greatly improves the compressive and bending strength of the board and ensures the structural stability during long-term use.

[0042] The main sound insulation layer 30 is made of closed-cell phenolic foam, which significantly suppresses the penetration of low-frequency noise.

[0043] It should be noted that the closed-cell phenolic foam is an existing material. Specifically, those skilled in the art can refer to the Chinese invention patent with publication number CN117700921A entitled "A high closed-cell rate, high efficiency, energy-saving and fire-retardant phenolic foam and its preparation method".

[0044] The nano aluminum hydroxide coating of the fireproof layer 50 gives the sound insulation board excellent flame retardant and smoke suppression properties, meeting high fire protection standards.

[0045] It should be noted that the nano-aluminum hydroxide is an existing material. Specifically, those skilled in the art can refer to Chinese invention patent CN101746787A entitled "A method for preparing nano-aluminum hydroxide and its application".

[0046] The bottom aluminum foil reflective layer further blocks the noise transmission path through sound wave reflection;

[0047] Through the cooperation of various layers, a multi-layered noise reduction mechanism of "sound absorption-blocking-reflection" is formed, which can be widely used in building and industrial scenarios, and is both environmentally friendly and economical.

[0048] In one embodiment, such as Figure 1 and Figure 2 As shown, the hemispherical grooves 11 are regularly distributed on the surface of the surface sound-absorbing layer 10, with a diameter of 4-6 mm and a depth of 2-3 mm.

[0049] In this solution, the sound wave reflection path can be optimized through regular size design, reducing energy penetration and improving the overall noise reduction coefficient.

[0050] In one embodiment, such as Figure 1 As shown, ceramic microspheres 31 are dispersed inside the main sound insulation layer 30.

[0051] Specifically, the ceramic microspheres 31 are uniformly dispersed inside the main sound insulation layer 30.

[0052] It should be noted that the ceramic microspheres 31 are existing materials. For the design of the main sound insulation layer 30 with ceramic microspheres 31 dispersed inside, similar to other commonly used fillers for filling phenolic foam, in the mixing step before the raw material foaming, the phenolic resin and foaming agent are mixed and foamed, and the ceramic microspheres 31 are pre-embedded. After foaming and curing, closed-cell phenolic foam with ceramic microspheres 31 embedded inside can be obtained. This is an existing conventional filler filling method, which will not be elaborated here.

[0053] In one embodiment, the volume of the ceramic microspheres 31 accounts for 5%-8% of the volume of the main sound insulation layer 30.

[0054] In one embodiment, the ceramic microspheres 31 have a particle size of 0.5-2 mm.

[0055] In the above scheme, ceramic microspheres 31 are dispersed inside the main sound insulation layer 30. The ceramic microspheres significantly improve the attenuation effect of low-frequency noise through sound wave scattering and refraction. The uniformly dispersed particle structure can disrupt the continuous transmission path of sound waves. At the same time, the rigidity of the microspheres enhances the compressive strength of the closed-cell phenolic foam and avoids interlayer deformation.

[0056] In one embodiment, the density of the closed-cell phenolic foam is 60-80 kg / m³. 3 Thermal conductivity ≤0.025W / (m·K).

[0057] The above solution combines lightweight and sound insulation performance through a low-density closed-cell structure, while simultaneously improving thermal insulation performance with a low thermal conductivity, making it suitable for scenarios with dual requirements for sound insulation and heat insulation.

[0058] In one embodiment, the surfaces of the first reinforcing layer 20 and the second reinforcing layer 40 away from the main sound insulation layer 30 are coated with modified epoxy resin.

[0059] Using the above method, the modified epoxy resin, after curing, forms a rigid composite layer with the glass fiber mesh, which greatly improves the bending strength and impact resistance, while preventing the fiber layer from absorbing moisture and aging, thus extending its service life.

[0060] It should be noted that the modified epoxy resin is an existing material. Specifically, those skilled in the art can refer to the Chinese invention patent "Modified Epoxy Resin, Preparation Method Thereof and Modified Epoxy Resin Board" with publication number CN109734878A.

[0061] In one embodiment, the thickness of the surface sound-absorbing layer 10 is 3-5 mm; the thickness of the main sound-insulating layer 30 is 15-25 mm; and the thickness of the bottom reflective layer 60 is 0.1-0.3 mm.

[0062] By adopting the above solution, the surface thickness is controlled to ensure the acoustic effect of the sound-absorbing groove, the main layer thickness is matched to the low-frequency sound insulation requirements, and the ultra-thin aluminum foil design of the bottom layer ensures the reflection efficiency while avoiding increasing the overall weight, thus achieving a balance between performance and lightweight.

[0063] In one embodiment, such as Figure 3 As shown, the outer periphery of the phenolic foam sound insulation board is provided with an edge connection structure 70; the edge connection structure 70 includes a protrusion 71 and a recess 72 that can wedge into each other.

[0064] In one embodiment, the cross-sections of the protrusion 71 and the recess 72 are one of trapezoidal, rectangular, triangular and stepped structures.

[0065] like Figure 3 As shown, an edge connection structure 70 is provided. The splicing process is simplified by the design of the interlocking protrusions 71 and concave parts 72. Quick installation can be achieved without additional fasteners, making the assembly more convenient and stable.

[0066] It should be noted that the selection of the cross-sectional shape of the protrusion 71 and the concave part 72 can meet the requirements of quick and easy assembly, including but not limited to the cross-sectional shape selection provided in this embodiment.

[0067] Furthermore, through verification experiments and comparative analysis, the effectiveness of the phenolic foam sound insulation board provided by this utility model can be verified:

[0068] The verification test samples are as follows:

[0069] From top to bottom, it includes a surface sound-absorbing layer 10, a first reinforcing layer 20, a main sound insulation layer 30, a second reinforcing layer 40, a fireproof layer 50, and a bottom reflective layer 60.

[0070] The surface sound-absorbing layer 10 is made of open-cell phenolic foam with a thickness of 3-5mm, and its surface is provided with a hemispherical groove 11 with a diameter of 5mm and a depth of 2.5mm.

[0071] The main sound insulation layer 30 has a thickness of 15-25mm and is made of closed-cell phenolic foam with a density of 80kg / m³ and a thermal conductivity of ≤0.025W / (m·K). It also incorporates ceramic microspheres 31 with a particle size of 1mm at a volume ratio of 6% of the main sound insulation layer 30.

[0072] The first reinforcing layer 20 and the second reinforcing layer 40 are made of fiberglass mesh cloth, which are embedded in the upper and lower surfaces of the main sound insulation layer 30, respectively, and the surfaces are coated with modified epoxy resin and cured.

[0073] The fireproof layer 50 is made of nano aluminum hydroxide coating and is applied to the side of the second reinforcing layer 40 away from the main sound insulation layer 30;

[0074] The bottom reflective layer 60 is made of 0.2mm aluminum foil film and covers the side of the fireproof layer 50 away from the main sound insulation layer 30;

[0075] The outer periphery of the phenolic foam sound insulation board is provided with an edge connection structure 70; the edge connection structure 70 includes a protrusion 71 and a recess 72 that can wedge into each other, and the cross-section of the protrusion 71 and the recess 72 is rectangular.

[0076] Test results:

[0077] Test results show that the noise reduction coefficient (NRC) of this sample is 0.85; compressive strength is ≥200kPa; flexural strength is ≥1.5MPa; and the combustion performance meets the A2 non-combustible standard (GB 8624-2012).

[0078] In summary, the phenolic foam sound insulation board provided by this utility model has the following beneficial effects:

[0079] Through a multi-layered composite structure design, the sound insulation performance, strength, and fire resistance of the sound insulation board are effectively improved. The open-cell phenolic foam of the surface sound-absorbing layer, combined with hemispherical grooves, enhances sound wave scattering and absorption efficiency, especially for mid-to-high frequency noise, forming multi-level attenuation. The closed-cell phenolic foam of the main sound insulation layer significantly inhibits the penetration of low-frequency noise, while the double-layer embedding of fiberglass mesh greatly improves the compressive and bending strength of the board, ensuring structural stability during long-term use. The nano-aluminum hydroxide coating of the fireproof layer gives the sound insulation board excellent flame retardant and smoke suppression properties, meeting high fire protection standards. The bottom aluminum foil reflective layer further blocks the noise transmission path through sound wave reflection, forming a multi-layer noise reduction mechanism of "sound absorption-blocking-reflection". In addition, the composite of each functional layer takes into account both lightweight and durability, and can be widely used in building and industrial scenarios, combining environmental protection and economy.

[0080] Although this document frequently uses terms such as surface sound-absorbing layer, first reinforcing layer, main sound-insulating layer, second reinforcing layer, fireproof layer, and bottom reflective layer, the possibility of using other terms is not excluded. These terms are used merely for the convenience of describing and explaining the essence of this invention; interpreting them as any additional limitation would contradict the spirit of this invention.

[0081] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. A phenolic foam sound insulation board, characterized in that: From top to bottom, it includes a surface sound-absorbing layer, a first reinforcing layer, a main sound insulation layer, a second reinforcing layer, a fireproof layer, and a bottom reflective layer; The surface sound-absorbing layer is made of open-cell phenolic foam, and its surface is provided with hemispherical grooves. The main sound insulation layer is made of closed-cell phenolic foam; The first and second reinforcing layers are made of fiberglass mesh and are embedded in the upper and lower surfaces of the main sound insulation layer, respectively. The fireproof layer is made of nano-aluminum hydroxide coating and is applied to the side of the second reinforcing layer away from the main sound insulation layer. The bottom reflective layer is made of aluminum foil and covers the side of the fireproof layer away from the main sound insulation layer.

2. The phenolic foam sound insulation board according to claim 1, characterized in that: The hemispherical grooves are regularly distributed on the surface of the sound-absorbing layer, with a diameter of 4-6 mm and a depth of 2-3 mm.

3. The phenolic foam sound insulation board according to claim 1, characterized in that: The main sound insulation layer contains dispersed ceramic microspheres.

4. The phenolic foam sound insulation board according to claim 3, characterized in that: The ceramic microspheres have a particle size of 0.5-2 mm.

5. The phenolic foam sound insulation board according to claim 1, characterized in that: The density of the closed-cell phenolic foam is 60-80 kg / m³. 3 Thermal conductivity ≤0.025W / (m·K).

6. The phenolic foam sound insulation board according to claim 1, characterized in that: The surfaces of the first and second reinforcing layers away from the main sound insulation layer are coated with modified epoxy resin.

7. The phenolic foam sound insulation board according to claim 1, characterized in that: The thickness of the surface sound-absorbing layer is 3-5mm; the thickness of the main sound insulation layer is 15-25mm; and the thickness of the bottom reflective layer is 0.1-0.3mm.

8. The phenolic foam sound insulation board according to claim 1, characterized in that: The outer periphery of the phenolic foam sound insulation board is provided with an edge connection structure; the edge connection structure includes convex and concave parts that can wedge into each other.

9. The phenolic foam sound insulation board according to claim 8, characterized in that: The cross-sections of the convex and concave parts are one of trapezoidal, rectangular, triangular, and stepped structures.

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