CN112248560A - 一种隔音环保建筑材料及其制备方法 - Google Patents

一种隔音环保建筑材料及其制备方法 Download PDF

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CN112248560A
CN112248560A CN202011089800.7A CN202011089800A CN112248560A CN 112248560 A CN112248560 A CN 112248560A CN 202011089800 A CN202011089800 A CN 202011089800A CN 112248560 A CN112248560 A CN 112248560A
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foamed aluminum
open
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sound
flexible material
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CN112248560B (zh
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云广川
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Guangdong Fengzhou Construction Co ltd
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  • Acoustics & Sound (AREA)
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Abstract

本发明涉及建筑材料技术领域，具体涉及一种隔音环保建筑材料及其制备方法。该隔音环保建筑材料包括柔性材料层以及泡沫铝层，所述柔性材料层与泡沫铝层之间采用非胶黏剂固接；所述泡沫铝层选择为平均孔径为6‑12mm的开孔泡沫铝。所述柔性材料层为一侧附接有魔术贴毛面的无纺布、土工布、机织物等；所述泡沫铝层的表面附接有双面钩面扣带。本发明制得的隔音环保建筑材料具有质量轻、隔音、电磁屏蔽等优势，同时，表面采用柔性材料，能够起到一定的防护作用，可广泛用于建筑隔音、房屋装修、隔音墙板等，大大扩展了泡沫铝材料的应用范围和场景。

Description

一种隔音环保建筑材料及其制备方法
技术领域
本发明涉及建筑材料技术领域，具体涉及一种隔音环保建筑材料及其制备方法。
背景技术
随着社会发展，城市人口日益增加，越来越多的人们住进了高楼大厦。人口密度的增加，噪音也越来越多。在高楼之外，汽车穿梭于城市的各个角落。住宅小区内各户之间作息时间差异、广场舞大妈的音响、商贩的叫卖等等，都会发出各种各样的噪音。因此，在建筑房屋以及房屋装修时，隔离噪音就显得尤为重要。防治噪音的措施有多种，最简单的是去除噪声源。然而，大部分的噪音几乎不可能去除，例如汽车驶过时发出噪音，若杜绝汽车行驶，那又会带来其它问题。在现实生活中，防治噪音更多的还是依靠隔音材料，阻隔外界噪音，避免噪音对自己造成影响。在建筑领域中，隔音材料多种多样，包括混凝土墙、砌块墙、条板墙、薄板复合墙以及现场喷水泥砂浆面层的芯材板墙等，这些隔音材料已经广泛应用，根据应用的具体场合而选择合适的隔音材料。
泡沫铝是在纯铝或铝合金中加入添加剂后，经过发泡工艺而成，同时兼有金属和气泡特征。泡沫铝可以用作建筑及装潢材料，它具有质轻、高比刚度、美观、不燃烧等优点，并兼有吸音、隔热、电磁屏蔽等特性。因此泡沫铝可广泛应用于商场、宾馆、体育馆等场馆的建筑装潢。但泡沫铝的外表面遍布大小不同的凹坑，外观不够美观。在实际使用时，往往在表层加装面板和底板，将泡沫铝作为芯层，使其成为三明治结构。然而，在泡沫铝表面加装面板或底板，通常的做法是采用胶粘的方式进行粘接。如专利申请号为CN201610195205.9的发明专利，公开了一种竹材、木材与泡沫铝复合夹心板及其制作方法，其中公开的复合夹芯板材由面层、芯层、底层三层粘合压制而成的复合板材；泡沫铝作为芯层，竹材和/或木材作为面层或底层；或者是，泡沫铝作为芯层，泡沫铝的一面贴竹材和/或木材，泡沫铝的另一面直接与薄钢板一次成型。制作步骤包括对已制成的面层、底层材料的粘接面进行磨砂处理；对面层、底层板粘接面及芯层泡沫铝双面施胶；组坯；在压机上压制复合成型。然而，由于泡沫铝表面具有大量的凹坑，这种直接采用胶粘的方式需要消耗大量的胶黏剂，同时很多胶黏剂中会释放甲醛，不利于环保。另外，这种复合材料两面均为刚性材料，在某些需要注意防护的场景(如幼儿园、托儿所等)，容易磕碰到刚性表面从而出现伤害。目前还未发现有在泡沫铝表面复合柔性材料的复合材料出现。因此，如何在减少使用甚至不使用胶黏剂的情况下，制备包括泡沫铝成分和柔性材料的多层隔音环保建筑材料，是技术人员面临的一大问题。
发明内容
针对现有技术存在上述技术问题，本发明提出了一种隔音环保建筑材料及其制备方法，制得的建筑材料具有质量轻、隔音、电磁屏蔽等优势，同时，表面采用柔性材料，能够起到一定的防护作用，可广泛用于建筑隔音、房屋装修、隔音墙板等，大大扩展了泡沫铝材料的应用范围和场景。
为解决现有技术中的技术问题，实现这些目的，本发明提供了如下技术方案：
一种隔音环保建筑材料，包括柔性材料层以及泡沫铝层；所述柔性材料层与泡沫铝层之间采用非胶黏剂固接；所述泡沫铝层选择为平均孔径为6-12mm的开孔泡沫铝。
进一步的，所述柔性材料层为一侧附接有魔术贴毛面的无纺布、土工布或机织物，厚度为4-20mm。
本发明还提供了一种隔音环保建筑材料的制备方法，包括如下步骤：
(1)原料准备：
准备厚度为10-50mm、平均孔径为6-12mm的开孔泡沫铝；
准备熔点为132-135℃范围的聚乙烯颗粒，其平均粒径为0.5-2mm；
准备长度为9-15mm且直径为0.5-1mm的不锈钢丝；
准备芯层为聚对苯二甲酸丁二酯或聚对苯二甲酸乙二醇酯、皮层为聚乙烯的皮芯纤维，所述皮芯纤维的长度为15-25mm，线密度为1.8-2.5dtex；所述皮层的聚乙烯的熔点为112℃；
选择一侧附接有魔术贴毛面的无纺布、土工布或机织物作为柔性材料，所述柔性材料的厚度为4-20mm；所述附接的方式采用缝编技术实现；
准备双面钩面扣带，所述双面钩面扣带的两侧均具有T形联锁元件，所述T形联锁元件高度为0.5-1mm，宽度为0.5-1mm，单侧所述T形联锁元件的面密度为55-80个/平方厘米；位于两侧T形联锁元件之间的基体的厚度为0.1-0.3mm；所述双面钩面扣带能够在160℃以下温度保持形态良好且不熔化；
准备由金属丝经纬交织形成金属网，所述金属网的目数为6-12，所述金属丝直径为0.3-0.6mm；
(2)金属网预处理：将所述皮芯纤维通过梳理机梳理形成纤维网，铺设纤维网2-4层后放置所述金属网，之后再在金属网上方铺放2-4层纤维网；之后进行水刺，使皮芯纤维与金属网发生交缠，之后在50-70℃下烘干备用；
(3)开孔泡沫铝预处理：将所述开孔泡沫铝平铺，再在其上均匀撒上不锈钢丝，使得所述开孔泡沫铝表面的各个孔中均存在1-3根不锈钢丝；之后再均匀撒上聚乙烯颗粒，使所述聚乙烯颗粒基本充满所述开孔泡沫铝表面开孔体积；然后送入烘箱加热至温度为138-140℃，保持10-20min，使聚乙烯颗粒熔融，之后冷却定型；由于不锈钢丝的长度大于开孔泡沫铝的平均孔径，使得冷却定型后的开孔泡沫铝的表面突出有一定长度的不锈钢丝；
(4)形成粘结层：将步骤(2)得到的经过预处理的金属网以及所述双面钩面扣带依次紧密地覆盖在步骤(3)得到的经过预处理的开孔泡沫铝上，突出于开孔泡沫铝表面的不锈钢丝依次穿过金属网的网孔和双面钩面扣带的基体，并使得双面钩面扣带与金属网接触的一侧T形联锁元件插入金属网的网孔中；之后再次送入烘箱加热至温度为115-120℃，保持10-20min，使金属网上的皮芯纤维的皮层聚乙烯熔融，之后冷却定型，由此得到具有粘结层的开孔泡沫铝；
(5)辊压：利用表面光滑的轧辊对步骤(4)得到的具有粘结层的开孔泡沫铝进行辊压；辊压时，轧辊表面与所述双面钩面扣带的基体表面之间保持0.5-1mm的间距，使突出于双面钩面扣带的不锈钢丝被轧辊压弯；
(6)柔性材料附接：将一侧附接有魔术贴毛面的柔性材料与所述双面钩面扣带附接，从而形成表面具有柔性材料的隔音环保建筑材料。
在步骤(3)开孔泡沫铝预处理时，位于开孔泡沫铝表面的各个孔中的聚乙烯颗粒熔融之后再冷却，使得位于开孔泡沫铝表面的各个孔中的不锈钢丝能够牢固地固定在开孔泡沫铝表面的各个孔中。由于不锈钢丝的长度大于开孔泡沫铝表面的平均孔径，这使得不锈钢丝会有部分长度突出于开孔泡沫铝的表面。进一步的，所述不锈钢丝可以选择具有轻微弯曲的形状，如波浪形等。这能够进一步增加牢固度。
在步骤(4)形成粘结层时，再次加热使得皮芯纤维的皮层聚乙烯熔融，而皮芯纤维的芯层采用聚对苯二甲酸丁二酯或聚对苯二甲酸乙二醇酯制成，其熔点远高于皮层聚乙烯，这使得缠绕在金属网上的皮芯纤维只是皮层熔融；由于双面钩面扣带的一侧T形联锁元件插入金属网的网孔中，同时开孔泡沫铝表面的孔中也充满了熔点稍高的聚乙烯，这使得熔融后的皮芯纤维皮层的聚乙烯能够与开孔泡沫铝表面的孔中的聚乙烯粘结在一起，也使得插入金属网的网孔中的T形联锁元件也粘合在金属网的网孔中，并通过突出于开孔泡沫铝表面的不锈钢丝穿过金属网的网孔和双面钩面扣带的基体而进一步将双面钩面扣带与开孔泡沫铝固定在一起。而由于皮芯纤维的芯层没有熔融，这也使得皮芯纤维的芯层部分能够牢牢地固定金属网。
在步骤(5)辊压时，由于开孔泡沫铝表面的开孔大小尺寸不同，穿过并突出于双面钩面扣带的不锈钢丝的长度不一。采用辊压的方式，并使轧辊表面与双面钩面扣带的基体表面之间保持合理的间距，能够使得不锈钢丝被轧辊压弯，利于后续柔性材料的附接。
进一步的，所述隔音环保建筑材料采用模块化生产，所述开孔泡沫铝的长度为40-80cm,宽度为40-80cm；所述一侧附接有魔术贴毛面的柔性材料以及双面钩面扣带的长度和宽度与所述开孔泡沫铝的长度和宽度相匹配。采用模块化生产，能够在使用时实现拼接化作业，方便施工。拼接方式可以采用拼图的方式进行拼接。
进一步的，所述双面钩面扣带的T形联锁元件采用聚对苯二甲酸丁二酯或聚对苯二甲酸乙二醇酯制成。聚对苯二甲酸丁二酯、聚对苯二甲酸乙二醇酯的熔点较高且易于生产，能够满足双面钩面扣带的T形联锁元件的强度、耐久性等性能要求。
进一步的，所述一侧附接有魔术贴毛面的柔性材料，其另一侧表面平整且具有印花图案，所述印花图案为相同或不同的图案。当为不同的图案时，可通过拼接的方式形成墙画。采用一侧附接有魔术贴毛面的柔性材料与T形联锁元件通过粘贴的方式附接，能够方便地更换柔性材料。当柔性材料被损坏、或者不喜欢其表面的印花图案等时，可以随时根据喜好而进行更换，避免了现有建筑装修中，装修风格或图案难以变更的问题。
更进一步的，所述一侧附接有魔术贴毛面的柔性材料，其另一侧表面平整且附接有聚氨酯薄膜。在柔性材料的另一侧附接聚氨酯薄膜，能够提高柔性材料的防水性、弹性以及亲肤性等，更有利于防护。
更进一步的，所述双面钩面扣带的基体采用聚对苯二甲酸丁二酯或聚对苯二甲酸乙二醇酯制成。所述双面钩面扣带的基体采用与双面钩面扣带的T形联锁元件相同的材质制成，利于双面钩面扣带的生产，且在本发明的制备过程中不会发生熔融变形等。
有益效果
与现有技术相比，本发明至少具有如下有益效果：
(1)本发明提供了一种隔音环保建筑材料及其制备方法，制得的建筑材料具有质量轻、隔音、电磁屏蔽等优势，同时，表面采用柔性材料，能够起到一定的防护作用，可广泛用于建筑隔音、房屋装修、隔音墙板等，大大扩展了泡沫铝材料的应用范围和场景。
(2)本发明中不采用胶黏剂，采用非胶黏剂的方式使柔性材料附着在开孔泡沫铝上，避免了胶黏剂中甲醛等有害物质的释放，有利于环保。
(3)本发明中巧妙地采用魔术贴的方式进行粘接，合理地选择原料及各种参数，将刚性材料开孔泡沫铝与柔性材料可替换的连接在一起。在将该材料用于建筑装修时，能够根据个人喜好随时更换不同的柔性材料，解决了现有技术中的建筑装修风格难以简单更换的问题。
(4)本发明的隔音环保建筑材料，充分利用了泡沫铝的隔音特性和柔性材料的柔软防护性能，也能够用于幼儿园、托儿所等需要对幼儿进行防护的场景，同时其隔音性能也非常适合幼儿园、托儿所等环境需要。
(5)本发明的隔音环保建筑材料可以采用模块化生产，将尺寸控制在一定范围内，便于使用时的运输、安装、拼接以及可替换。将具有多种不同(如表面印花图案不同)的柔性材料的隔音环保建筑材料进行拼接，能够组合成不同的装修风格。也可以采用类似拼图的方式对隔音环保建筑材料进行模块化生产，如此即可简单地形成墙画。
(6)本发明所采用的制备方法，特别适合平均孔径为6-12mm的开孔泡沫铝。该孔径范围较大，双面钩面扣带的T形联锁元件尺寸较小，直接采用聚乙烯颗粒熔融固定，将影响其牢固程度。本发明中，巧妙地采用不锈钢丝、金属网、以及皮芯纤维等，使得具有较大平均孔径的开孔泡沫铝依然能够牢固固定双面钩面扣带。
具体实施方式
以下结合具体实施例对本发明进行详细说明。
实施例一：本实施例提供一种隔音环保建筑材料的制备方法，包括如下步骤：
(1)原料准备：
准备厚度为10mm、平均孔径为6mm的开孔泡沫铝；开孔泡沫铝的长度为40cm,宽度为40cm。
准备熔点为132℃的聚乙烯颗粒，其平均粒径为0.5mm。
准备长度为9mm且直径为0.5mm的不锈钢丝。
准备芯层为聚对苯二甲酸丁二酯、皮层为聚乙烯的皮芯纤维，皮芯纤维的长度为15mm，线密度为1.8dtex；皮层的聚乙烯的熔点为112℃。
选择一侧附接有魔术贴毛面的无纺布作为柔性材料，柔性材料的厚度为4mm；采用缝编技术将魔术贴毛面与无纺布缝合在一起而形成柔性材料，魔术贴毛面背离无纺布的表面而露在外面；柔性材料的另一侧表面平整且具有印花图案，印花图案为相同的图案，例如卡通、花草、人物等图案。
准备双面钩面扣带，双面钩面扣带的两侧均具有T形联锁元件，T形联锁元件高度为0.5mm，宽度为0.5mm，单侧T形联锁元件的面密度为80个/平方厘米；位于两侧T形联锁元件之间的基体的厚度为0.1mm；双面钩面扣带能够在160℃以下温度保持形态良好且不熔化；双面钩面扣带的T形联锁元件以及基体均采用聚对苯二甲酸丁二酯制成；一侧附接有魔术贴毛面的柔性材料以及双面钩面扣带的长度和宽度与开孔泡沫铝的长度和宽度相匹配。其中，双面钩面扣带的制备属于现有技术，可参考专利文献CN110225708A，在此全文引入，并不再赘述。
准备由金属丝经纬交织形成金属网，金属网的目数为12，金属丝直径为0.3mm。
(2)金属网预处理：将皮芯纤维通过梳理机梳理形成纤维网，铺设纤维网2层后放置金属网，之后再在金属网上方铺放2层纤维网；之后进行水刺，使皮芯纤维与金属网发生交缠，之后在50℃下烘干备用。
(3)开孔泡沫铝预处理：将开孔泡沫铝平铺，再在其上均匀撒上不锈钢丝，使得开孔泡沫铝表面的各个孔中均存在1-3根不锈钢丝；之后再均匀撒上聚乙烯颗粒，使聚乙烯颗粒基本充满开孔泡沫铝表面开孔体积；然后送入烘箱加热至温度为138℃，保持10min，使聚乙烯颗粒熔融，之后冷却定型；由于不锈钢丝的长度大于开孔泡沫铝的平均孔径，使得冷却定型后的开孔泡沫铝的表面突出有一定长度的不锈钢丝。
(4)形成粘结层：将步骤(2)得到的经过预处理的金属网以及双面钩面扣带依次紧密地覆盖在步骤(3)得到的经过预处理的开孔泡沫铝上，突出于开孔泡沫铝表面的不锈钢丝依次穿过金属网的网孔和双面钩面扣带的基体，并使得双面钩面扣带与金属网接触的一侧T形联锁元件插入金属网的网孔中；之后再次送入烘箱加热至温度为115℃，保持10min，使金属网上的皮芯纤维的皮层聚乙烯熔融，之后冷却定型，由此得到具有粘结层的开孔泡沫铝。
(5)辊压：利用表面光滑的轧辊对步骤(4)得到的具有粘结层的开孔泡沫铝进行辊压；辊压时，轧辊表面与双面钩面扣带的基体表面之间保持0.5mm的间距，使突出于双面钩面扣带的不锈钢丝被轧辊压弯。
(6)柔性材料附接：将一侧附接有魔术贴毛面的柔性材料与双面钩面扣带附接，从而形成表面具有柔性材料的隔音环保建筑材料。
实施例二：本实施例提供一种隔音环保建筑材料的制备方法，包括如下步骤：
(1)原料准备：
准备厚度为30mm、平均孔径为9mm的开孔泡沫铝；开孔泡沫铝的长度为60cm,宽度为60cm。
准备熔点为134℃的聚乙烯颗粒，其平均粒径为1mm。
准备长度为12mm且直径为0.8mm的不锈钢丝。
准备芯层为聚对苯二甲酸乙二醇酯、皮层为聚乙烯的皮芯纤维，皮芯纤维的长度为20mm，线密度为2dtex；皮层的聚乙烯的熔点为112℃。
选择一侧附接有魔术贴毛面的土工布作为柔性材料，柔性材料的厚度为12mm；采用缝编技术将魔术贴毛面与土工布缝合在一起而形成柔性材料，魔术贴毛面背离土工布的表面而露在外面；柔性材料的另一侧表面平整且具有印花图案，印花图案为不同的图案，并且这些不同的图案能够拼接成一幅完整的画。
准备双面钩面扣带，双面钩面扣带的两侧均具有T形联锁元件，T形联锁元件高度为0.7mm，宽度为0.7mm，单侧T形联锁元件的面密度为65个/平方厘米；位于两侧T形联锁元件之间的基体的厚度为0.2mm；双面钩面扣带能够在160℃以下温度保持形态良好且不熔化；双面钩面扣带的T形联锁元件以及基体均采用聚对苯二甲酸乙二醇酯制成。一侧附接有魔术贴毛面的柔性材料以及双面钩面扣带的长度和宽度与开孔泡沫铝的长度和宽度相匹配。
准备由金属丝经纬交织形成金属网，金属网的目数为9，金属丝直径为0.5mm。
(2)金属网预处理：将皮芯纤维通过梳理机梳理形成纤维网，铺设纤维网3层后放置金属网，之后再在金属网上方铺放3层纤维网；之后进行水刺，使皮芯纤维与金属网发生交缠，之后在60℃下烘干备用。
(3)开孔泡沫铝预处理：将开孔泡沫铝平铺，再在其上均匀撒上不锈钢丝，使得开孔泡沫铝表面的各个孔中均存在1-3根不锈钢丝；之后再均匀撒上聚乙烯颗粒，使聚乙烯颗粒基本充满开孔泡沫铝表面开孔体积；然后送入烘箱加热至温度为139℃，保持15min，使聚乙烯颗粒熔融，之后冷却定型；由于不锈钢丝的长度大于开孔泡沫铝的平均孔径，使得冷却定型后的开孔泡沫铝的表面突出有一定长度的不锈钢丝。
(4)形成粘结层：将步骤(2)得到的经过预处理的金属网以及双面钩面扣带依次紧密地覆盖在步骤(3)得到的经过预处理的开孔泡沫铝上，突出于开孔泡沫铝表面的不锈钢丝依次穿过金属网的网孔和双面钩面扣带的基体，并使得双面钩面扣带与金属网接触的一侧T形联锁元件插入金属网的网孔中；之后再次送入烘箱加热至温度为118℃，保持15min，使金属网上的皮芯纤维的皮层聚乙烯熔融，之后冷却定型，由此得到具有粘结层的开孔泡沫铝。
(5)辊压：利用表面光滑的轧辊对步骤(4)得到的具有粘结层的开孔泡沫铝进行辊压；辊压时，轧辊表面与双面钩面扣带的基体表面之间保持0.7mm的间距，使突出于双面钩面扣带的不锈钢丝被轧辊压弯。
(6)柔性材料附接：将一侧附接有魔术贴毛面的柔性材料与双面钩面扣带附接，从而形成表面具有柔性材料的隔音环保建筑材料。
实施例三：本实施例提供一种隔音环保建筑材料的制备方法，包括如下步骤：
(1)原料准备：
准备厚度为50mm、平均孔径为12mm的开孔泡沫铝；开孔泡沫铝的长度为80cm,宽度为80cm。
准备熔点为135℃范围的聚乙烯颗粒，其平均粒径为2mm。
准备长度为15mm且直径为1mm的不锈钢丝。
准备芯层为聚对苯二甲酸乙二醇酯、皮层为聚乙烯的皮芯纤维，皮芯纤维的长度为25mm，线密度为2.5dtex；皮层的聚乙烯的熔点为112℃。
选择一侧附接有魔术贴毛面的机织物作为柔性材料，柔性材料的厚度为20mm；附接的方式采用缝编技术实现；该机织物的内部可以填充弹性蓬松纤维，或者采用多层机织物进行缝合以达到预定厚度。一侧附接有魔术贴毛面的柔性材料，其另一侧表面平整且附接有聚氨酯薄膜。
准备双面钩面扣带，双面钩面扣带的两侧均具有T形联锁元件，T形联锁元件高度为1mm，宽度为1mm，单侧T形联锁元件的面密度为55个/平方厘米；位于两侧T形联锁元件之间的基体的厚度为0.3mm；双面钩面扣带能够在160℃以下温度保持形态良好且不熔化；双面钩面扣带的T形联锁元件以及基体均采用聚对苯二甲酸乙二醇酯制成。一侧附接有魔术贴毛面的柔性材料以及双面钩面扣带的长度和宽度与开孔泡沫铝的长度和宽度相匹配。
准备由金属丝经纬交织形成金属网，金属网的目数为6，金属丝直径为0.6mm。
(2)金属网预处理：将皮芯纤维通过梳理机梳理形成纤维网，铺设纤维网4层后放置金属网，之后再在金属网上方铺放4层纤维网；之后进行水刺，使皮芯纤维与金属网发生交缠，之后在70℃下烘干备用。
(3)开孔泡沫铝预处理：将开孔泡沫铝平铺，再在其上均匀撒上不锈钢丝，使得开孔泡沫铝表面的各个孔中均存在1-3根不锈钢丝；之后再均匀撒上聚乙烯颗粒，使聚乙烯颗粒基本充满开孔泡沫铝表面开孔体积；然后送入烘箱加热至温度为140℃，保持20min，使聚乙烯颗粒熔融，之后冷却定型；由于不锈钢丝的长度大于开孔泡沫铝的平均孔径，使得冷却定型后的开孔泡沫铝的表面突出有一定长度的不锈钢丝。
(4)形成粘结层：将步骤(2)得到的经过预处理的金属网以及双面钩面扣带依次紧密地覆盖在步骤(3)得到的经过预处理的开孔泡沫铝上，突出于开孔泡沫铝表面的不锈钢丝依次穿过金属网的网孔和双面钩面扣带的基体，并使得双面钩面扣带与金属网接触的一侧T形联锁元件插入金属网的网孔中；之后再次送入烘箱加热至温度为120℃，保持20min，使金属网上的皮芯纤维的皮层聚乙烯熔融，之后冷却定型，由此得到具有粘结层的开孔泡沫铝。
(5)辊压：利用表面光滑的轧辊对步骤(4)得到的具有粘结层的开孔泡沫铝进行辊压；辊压时，轧辊表面与双面钩面扣带的基体表面之间保持1mm的间距，使突出于双面钩面扣带的不锈钢丝被轧辊压弯。
(6)柔性材料附接：将一侧附接有魔术贴毛面的柔性材料与双面钩面扣带附接，从而形成表面具有柔性材料的隔音环保建筑材料。
最后应当说明的是，以上实施例仅用以说明本发明的技术方案，而非对本发明保护范围的限制，尽管参照较佳实施例对本发明作了详细地说明，本领域的普通技术人员应当理解，可以对本发明的技术方案进行修改或者等同替换，而不脱离本发明技术方案的实质和范围。

Claims (8)

1.一种隔音环保建筑材料，包括柔性材料层以及泡沫铝层；其特征在于：所述柔性材料层与泡沫铝层之间采用非胶黏剂固接；所述泡沫铝层选择为平均孔径为6-12mm的开孔泡沫铝。
2.如权利要求1所述的隔音环保建筑材料，其特征在于：所述柔性材料层为一侧附接有魔术贴毛面的无纺布、土工布或机织物，厚度为4-20mm。
3.一种隔音环保建筑材料的制备方法，包括如下步骤：
(1)原料准备：
准备厚度为10-50mm、平均孔径为6-12mm的开孔泡沫铝；
准备熔点为132-135℃范围的聚乙烯颗粒，其平均粒径为0.5-2mm；
准备长度为9-15mm且直径为0.5-1mm的不锈钢丝；
准备芯层为聚对苯二甲酸丁二酯或聚对苯二甲酸乙二醇酯、皮层为聚乙烯的皮芯纤维，所述皮芯纤维的长度为15-25mm，线密度为1.8-2.5dtex；所述皮层的聚乙烯的熔点为112℃；
选择一侧附接有魔术贴毛面的无纺布、土工布或机织物作为柔性材料，所述柔性材料的厚度为4-20mm；所述附接的方式采用缝编技术实现；
准备双面钩面扣带，所述双面钩面扣带的两侧均具有T形联锁元件，所述T形联锁元件高度为0.5-1mm，宽度为0.5-1mm，单侧所述T形联锁元件的面密度为55-80个/平方厘米；位于两侧T形联锁元件之间的基体的厚度为0.1-0.3mm；所述双面钩面扣带能够在160℃以下温度保持形态良好且不熔化；
准备由金属丝经纬交织形成金属网，所述金属网的目数为6-12，所述金属丝直径为0.3-0.6mm；
(2)金属网预处理：将所述皮芯纤维通过梳理机梳理形成纤维网，铺设纤维网2-4层后放置所述金属网，之后再在金属网上方铺放2-4层纤维网；之后进行水刺，使皮芯纤维与金属网发生交缠，之后在50-70℃下烘干备用；
(3)开孔泡沫铝预处理：将所述开孔泡沫铝平铺，再在其上均匀撒上不锈钢丝，使得所述开孔泡沫铝表面的各个孔中均存在1-3根不锈钢丝；之后再均匀撒上聚乙烯颗粒，使所述聚乙烯颗粒基本充满所述开孔泡沫铝表面开孔体积；然后送入烘箱加热至温度为138-140℃，保持10-20min，使聚乙烯颗粒熔融，之后冷却定型；由于不锈钢丝的长度大于开孔泡沫铝的平均孔径，使得冷却定型后的开孔泡沫铝的表面突出有一定长度的不锈钢丝；
(4)形成粘结层：将步骤(2)得到的经过预处理的金属网以及所述双面钩面扣带依次紧密地覆盖在步骤(3)得到的经过预处理的开孔泡沫铝上，突出于开孔泡沫铝表面的不锈钢丝依次穿过金属网的网孔和双面钩面扣带的基体，并使得双面钩面扣带与金属网接触的一侧T形联锁元件插入金属网的网孔中；之后再次送入烘箱加热至温度为115-120℃，保持10-20min，使金属网上的皮芯纤维的皮层聚乙烯熔融，之后冷却定型，由此得到具有粘结层的开孔泡沫铝；
(5)辊压：利用表面光滑的轧辊对步骤(4)得到的具有粘结层的开孔泡沫铝进行辊压；辊压时，轧辊表面与所述双面钩面扣带的基体表面之间保持0.5-1mm的间距，使突出于双面钩面扣带的不锈钢丝被轧辊压弯；
(6)柔性材料附接：将一侧附接有魔术贴毛面的柔性材料与所述双面钩面扣带附接，从而形成表面具有柔性材料的隔音环保建筑材料。
4.如权利要求3所述的隔音环保建筑材料的制备方法，其特征在于：所述隔音环保建筑材料采用模块化生产，所述开孔泡沫铝的长度为40-80cm,宽度为40-80cm；所述一侧附接有魔术贴毛面的柔性材料以及双面钩面扣带的长度和宽度与所述开孔泡沫铝的长度和宽度相匹配。
5.如权利要求3或4所述的隔音环保建筑材料的制备方法，其特征在于：所述双面钩面扣带的T形联锁元件采用聚对苯二甲酸丁二酯或聚对苯二甲酸乙二醇酯制成。
6.如权利要求3-5任一项所述的隔音环保建筑材料的制备方法，其特征在于：所述一侧附接有魔术贴毛面的柔性材料，其另一侧表面平整且具有印花图案，所述印花图案为相同或不同的图案。
7.如权利要求3-5任一项所述的隔音环保建筑材料的制备方法，其特征在于：所述一侧附接有魔术贴毛面的柔性材料，其另一侧表面平整且附接有聚氨酯薄膜。
8.如权利要求3-7任一项所述的隔音环保建筑材料的制备方法，其特征在于：所述双面钩面扣带的基体采用聚对苯二甲酸丁二酯或聚对苯二甲酸乙二醇酯制成。
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