CN113910710A - 具有隔音功能的建筑材料及其制备方法 - Google Patents

具有隔音功能的建筑材料及其制备方法 Download PDF

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CN113910710A
CN113910710A CN202111119594.4A CN202111119594A CN113910710A CN 113910710 A CN113910710 A CN 113910710A CN 202111119594 A CN202111119594 A CN 202111119594A CN 113910710 A CN113910710 A CN 113910710A
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layer
sound
gas
polyurethane
building material
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CN113910710B (zh
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徐丽丽
刘岩
辛斌杰
周园园
严庆帅
周曦
于佳
谢翔宇
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Shanghai University of Engineering Science
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Shanghai University of Engineering Science
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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Laminated Bodies (AREA)
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Abstract

本发明提供了一种具有隔音功能的建筑材料及其制备方法，建筑材料从上至下依次包括上基层、硬质泡沫层、复合层和下基层，复合层由吸音层、聚氨酯弹性体层和隔音层组成，聚氨酯弹性体层包括水性聚氨酯、二氧化硅气凝胶、若干支撑组件和减震组件，二氧化硅气凝胶分散在水性聚氨酯中，支撑组件和减震组件垂直等距分散在水性聚氨酯和二氧化硅气凝胶之间；本发明采取双层声屏障联合结构和聚氨酯弹性体层，噪音在传递过程中，声音通过数次的跨介质传播，致使声音能量逐步衰减或大量消耗，可以有效地阻挡和吸收噪音，隔音效果优异；本发明的建筑材料结构设计合理，内含硬质泡沫层，上基层和下基层的硬度较大，内部吸音层质地较轻，可随意裁剪，操作简便。

Description

具有隔音功能的建筑材料及其制备方法
技术领域
本发明属于建筑材料技术领域，具体涉及一种具有隔音功能的建筑材料及其制备方法。
背景技术
2015年4月世卫组织和欧盟合作研究中心公开了一份关于噪音对健康影响的全面报告《噪音污染导致的疾病负担》。尽管对象是欧盟等发达国家，但他们却第一次指出噪音污染不仅只是让人烦躁，睡眠质量差，更会引发或触发心脏病、耳鸣等疾病，从而减少人的寿命。噪音危害已成为继空气污染之后人类公认的第二健康杀手。
噪音在日常生活中随处可见，普通的隔音建筑材料减弱透射声能阻挡声音的传播，就不能如同吸音材料那样多孔、疏松、透气，相反它的材质应该是重而密实，如钢板、铅板、砖墙等一类材料。隔音材料材质的要求是密实无孔隙或缝隙，有较大的重量。由于这类隔音材料密实，难于吸收和透过声能而反射能强，所以其吸音性能差。由于硅气凝胶的低声速特性，它还是一种理想的声学延迟或高温隔音材料。该材料的声阻抗可变范围较大(103-107kg/m2·s)，是一种较理想的超声探测器的声阻耦合材料，如常用声阻匝Zp＝1.5×107kg/m2·s的压电陶瓷作为超声波的发生器和探测器，而空气的声阻只有400kg/m2·s。专利CN 111792907 A公开了一种墙面隔音材料的制造方法，利用植物纤维、泡沫混凝土、硅气凝胶及其添加剂和水泥-石膏料混合填料，制备了隔音效果优异、高温稳定性和粘结性良好的隔音材料颗粒。但是植物纤维的原材料处理工艺繁琐，与泡沫混凝土均需要粉碎和过筛过程，生产周期长。除此之外，产品形状为颗粒状，使用时与涂料通过简单的物理粘结作用结合在一起，粘结性不强且易分散不均匀，可能会影响材料的隔音效果。专利CN 103848609B公开了一种复合隔音板，由重量百分比的粉煤灰、树脂、纤维材料和金属材料铝镁等制成，能够阻断较低音频噪音的传播，但是添加无机金属材料，成本较一般材料高，且易造成材料的机械强度较差，此外，植物纤维易吸水导致发霉，在树脂间分布不均匀，与其他组分结合不紧密，造成隔音板使用寿命短，经济性较差。Alireza Dourbash等(Preparation andcharacterization of polyurethane/silica aerogel nanocomposite materials[J].Journal of Applied Polymer Science,2016.)采用二氧化硅气凝胶制备了一种具有隔音性能的聚氨酯/气凝胶复合材料，隔音性能优异，具有很高的强度和良好的耐腐蚀性能，气凝胶的加入，增加了聚氨酯表面和水滴之间的接触角，能够实现这些材料的阻水性能。
发明内容
针对现有技术中的不足，本发明提供了一种具有隔音功能的建筑材料用于解决现有的建筑材料隔音性能和环保性差的问题，能够有效对噪音进行吸收和阻隔，并且具有一定的保温和阻燃性能。
为达到上述目的，本发明的解决方案是：
一种具有隔音功能的建筑材料，其从上至下依次包括上基层、硬质泡沫层、复合层和下基层。
其中，复合层紧贴硬质泡沫层和下基层之间，复合层由吸音层(即第一声屏障)、聚氨酯弹性体层和隔音层(即第二声屏障)组成，聚氨酯弹性体层位于吸音层和隔音层之间(即聚氨酯弹性体层紧密贴合在第一声屏障与第二声屏障的内壁上)，聚氨酯弹性体层包括水性聚氨酯、二氧化硅气凝胶、支撑组件和减震组件，二氧化硅气凝胶分散在水性聚氨酯中，支撑组件和减震组件垂直等距分散在水性聚氨酯和二氧化硅气凝胶之间。
进一步地，聚氨酯弹性体层的制备过程：将二异氰酸酯、二元醇、丙酮和二月桂酸二丁基锡混合反应，得到混合液；在混合液中加入三乙胺进行中和反应，之后加入去离子水和乙二胺得到水性聚氨酯乳液；在水性聚氨酯乳液中加入二氧化硅气凝胶，得到二氧化硅气凝胶/水性聚氨酯体系；在二氧化硅气凝胶/水性聚氨酯体系中加入支撑组件和减震组件，常温下固化即可。实际上，支撑组件和减震组件在二氧化硅气凝胶/水性聚氨酯体系呈不流动状态时以等距分布的方式添加。
进一步地，二异氰酸酯选自异佛尔酮二异氰酸酯(IPDI)、甲苯二异氰酸酯(TDI)、二苯基甲烷二异氰酸酯(MDI)、二环己基甲烷二异氰酸酯(HMDI)或六亚甲基二异氰酸酯(HDI)中的一种以上。
进一步地，二元醇选自聚己内酯二醇、聚碳酸酯二元醇、聚己二酸丁二醇酯、聚丙二醇或聚硅氧烷二醇中的一种以上。
实际上，聚氨酯弹性体层具备耐臭氧、耐辐射、耐低温、粘结力强、消音、减震、隔热等优点。除此以外，还具备一定能的弹性性能和耐冲击性，并且聚氨酯弹性体质地轻，可替代部分其他的组成材料如硬度较大的上下基材的使用，以减轻材料整体的重量。在聚氨酯弹性体层的制备后期即固化过程中，可以在其内部填充支撑组件和减震组件，这是其它组成材料所不能满足的。
进一步地，支撑组件选自钢管、H型钢、角钢或硬质塑料中的一种以上。其中，硬质塑料的邵氏硬度D≥65。
进一步地，减震组件选自弹簧、橡胶或弹簧钢中的一种以上。
进一步地，吸音层为疏松、多孔的吸音板，可以为木质吸音板、矿棉吸音板或布艺吸音板中的一种以上。吸音层的厚度为0.1-0.15cm。
进一步地，隔音层选自隔音棉或隔音板中的一种以上，隔音层的厚度为0.1-0.15cm。
进一步地，硬质泡沫层选自聚氨酯塑料泡沫板、硅酸铝纤维板或聚乙烯泡沫塑料中的一种以上。硬质泡沫层为具有保温或阻燃作用的保护层，硬质泡沫层的厚度为0.05-0.1cm。
进一步地，上基层选自木质基材、塑料基材或铝合金基材中的一种以上。
进一步地，下基层选自刚性的木质基材、铝合金基材、塑钢、石膏板或硬质纤维板中的一种以上，下基层的厚度为0.15-0.2cm。
进一步地，刚性的木质基材选自细木工板、三聚氰胺板、木塑板或三合板中的一种以上。
进一步地，具有隔音功能的建筑材料还包括上支撑层和下支撑层，上支撑层紧贴上基层和硬质泡沫层之间，下支撑层紧贴复合层和下基层之间。上支撑层和下支撑层均选自多层高强度玻璃纤维网或烧结金属网中的一种以上。
一种上述的具有隔音功能的建筑材料的制备方法，其包括如下步骤：
(1)、制备上基材：在上基层的内侧平铺硬质泡沫层，通过胶合的方式连接在一起；
(2)、制备聚氨酯弹性体层：将二异氰酸酯、二元醇、丙酮和二月桂酸二丁基锡混合反应，得到混合液；在混合液中加入三乙胺进行中和反应，之后加入去离子水和乙二胺得到水性聚氨酯乳液；在水性聚氨酯乳液中加入二氧化硅气凝胶，在常温常压下搅拌20min后，平铺在模具中，待其呈不流动状态时以等距分布的方式填充0.01重量份的支撑组件和0.01重量份的减震组件，待其完全固化即可；
(3)、制备复合层：将吸音层、聚氨酯弹性体层和隔音层粘结在一起；
(4)、将上基层、硬质泡沫层、复合层和下基层通过粘结的形式复合，得到具有隔音功能的建筑材料。
进一步地，步骤(1)中，上基层选自木质基材、塑料基材或铝合金基材中的一种以上。
进一步地，步骤(1)中，硬质泡沫层选自聚氨酯塑料泡沫板、硅酸铝纤维板或聚乙烯泡沫塑料中的一种以上。
进一步地，步骤(2)中，支撑组件选自钢管、H型钢、角钢或硬质塑料中的一种以上。
进一步地，步骤(2)中，减震组件选自弹簧、橡胶或弹簧钢中的一种以上。
进一步地，步骤(3)中，吸音层选自木质吸音板、矿棉吸音板或布艺吸音板中的一种以上。
进一步地，步骤(3)中，隔音层选自隔音棉或隔音板中的一种以上。
进一步地，步骤(4)中，下基层选自刚性木质基材、铝合金基材、塑钢、石膏板或硬质纤维板中的一种以上。
由于采用上述方案，本发明的有益效果是：
第一、本发明采取双层声屏障联合结构、含支撑组件和减震组件的聚氨酯弹性体层，噪音在传递过程中，声音通过数次的跨介质传播，致使声音能量逐步衰减或大量消耗，可以有效地阻挡和吸收噪音，隔音效果优异。
第二、本发明的具有隔音功能的建筑材料取材环保，结构设计合理，制备简单，通过在外基材的内表面复合一层较硬的泡沫层，硬质泡沫层质地较轻，耐冲击性强且具有一定的减震功能，对材料起保护作用的同时使材料具备一定的阻燃、保温和保护作用，提高材料的功能多元化。另外，外表面的上基层和下基层的硬度较大，即上基材选用硬度较大的木质基材、塑料或铝合金中的一种以上，下基材为不易弯曲变形的刚性的木质基材、铝合金基材、塑钢、石膏板或硬质纤维板的一种以上，则内部吸音层质地较轻，可随意裁剪，操作简便。
附图说明
图1为本发明的具有隔音功能的建筑材料整体结构示意图。
图2为本发明的具有隔音功能的建筑材料整体结构的向半剖放大示意图。
图3为本发明的聚氨酯弹性体层的示意图。
图4为本发明的聚氨酯弹性体层的部分放大示意图。
具体实施方式
本发明提供了一种具有隔音功能的建筑材料及其制备方法。
如图1至图4所示，本发明的具有隔音功能的环保建筑材料，包括依次贴合设置的上基层1、硬质泡沫层3、复合层(即强化吸音层)和下基层8，复合层紧贴硬质泡沫层3，复合层包括吸音层4、聚氨酯弹性体层5和隔音层6，聚氨酯弹性体层5位于吸音层4和隔音层6之间。环保建筑材料通过吸音层4进行声音能量的吸收和阻隔，通过聚氨酯弹性体层5进行减震和声音初步的吸收，再经过隔音层6对剩余声波噪音进行进一步的削弱，使得材料充分发挥吸音和降噪的作用；经过吸音层4的声音通过聚氨酯弹性体层5进行减震和缓冲，赋予材料一定的刚性和韧性，延长材料的使用寿命。其中，聚氨酯弹性体层5腔内包括水性聚氨酯9、二氧化硅气凝胶10、若干支撑组件11和若干减震组件12。聚氨酯弹性体层5中二氧化硅气凝胶10分散在水性聚氨酯9中，二氧化硅气凝胶10质地较轻，低声速特性，其还是一种理想的声学延迟或高温隔音材料，纳米结构的气凝胶还可作为新型气体过滤，与其它材料不同的是该材料孔洞大小分布均匀，气孔率高，是一种高效气体过滤材料。支撑组件11和减震组件12等距贯穿分散在水性聚氨酯9和二氧化硅气凝胶10之间，通过吸音层4的声音，经过聚氨酯弹性体层5的进一步传递，实现对声音的弱化和缓冲，未被吸收的声音通过支撑组件11的孔洞传递到隔音层6，通过由吸音层4、聚氨酯弹性体层5和隔音层6组成的强化吸音层，一步一步地对声音进行吸收、削弱和消除，以实现完全的消除噪音，达到十分优异的隔音效果。
其中，吸音层4为疏松、多孔的吸音板，可以为木质吸音板、矿棉吸音板或布艺吸音板中的一种以上。吸音层4的厚度为0.1-0.15cm。
隔音层6选自隔音棉或隔音板中的一种以上，隔音层6的厚度为0.1-0.15cm。
硬质泡沫层3选自聚氨酯塑料泡沫板、硅酸铝纤维板或聚乙烯泡沫塑料中的一种以上。硬质泡沫层3为具有保温或阻燃作用的保护层，硬质泡沫层3的厚度为0.05-0.1cm。
上基层1选自木质基材、塑料基材或铝合金基材中的一种以上。
下基层8选自刚性的木质基材、铝合金基材、塑钢、石膏板或硬质纤维板中的一种以上，下基层8的厚度为0.15-0.2cm。
其中，刚性的木质基材选自细木工板、三聚氰胺板、木塑板或三合板中的一种以上。
实际上，聚氨酯弹性体层5的制备方法：称取13重量份二异氰酸酯、19重量份二元醇、4.5重量份丙酮(作为溶剂)和0.03重量份催化剂二月桂酸二丁基锡(DBTDL)，将上述组分加入到反应装置中，在90-115℃下搅拌反应2h；然后向混合液中加入1.2重量份三乙胺进行中和反应30min，再加入64重量份去离子水进行乳化和1.2重量份乙二胺进行扩链，制得水性聚氨酯9乳液；然后向上述组分中加入0.05重量份二氧化硅气凝胶10粉末，在常温常压下搅拌20min后，得到二氧化硅气凝胶/水性聚氨酯体系，平铺在模具中，待其混合体系呈不流动状态时，以等距分布的方式填充0.01重量份的支撑组件11和0.01重量份的减震组件12，完全固化后形成聚氨酯弹性体层5。
其中，二异氰酸酯选自IPDI、TDI、MDI、HMDI或HDI中的一种以上。
二元醇选自聚己内酯二醇、聚碳酸酯二元醇、聚己二酸丁二醇酯、聚丙二醇或聚硅氧烷二醇中的一种以上。
支撑组件11选自钢管、H型钢、角钢或硬质塑料中的一种以上。其中，硬质塑料的邵氏硬度D≥65。
减震组件12选自弹簧、橡胶或弹簧钢中的一种以上。
另外，环保建筑材料还包括上支撑层2和下支撑层7，上支撑层2紧密贴合在上基层1和硬质泡沫层3之间，起待定的制成和减震作用，下支撑层7紧密贴合在复合层和下基层8之间。上支撑层2和下支撑层7包括多层高强度玻璃纤维网或烧结金属网，高强度玻璃纤维网具有绝缘性好、耐热性强和抗腐蚀性好等优点，并且来源广泛、价格便宜，是现代支撑材料组件发展研究较深入的一类无机非金属材料。利用烧结金属网做支撑元件，可以实现钢铁厂废铁资源的有效利用，并且金属网之间彼此交联形成大小不均一的网腔，利于声音的分散，从而避免声波集中传递，具有一定的缓冲作用。
本发明的具有隔音功能的建筑材料的制备方法包括如下步骤：
(1)、制备上基材：在上基层1的内侧打磨至一定粗糙程度，在粗糙面上平铺一层硬质泡沫层3，通过胶合或热压的方法紧密连接上基层1与硬质泡沫层3；
(2)、制备聚氨酯弹性体层5：称取13重量份二异氰酸酯、19重量份二元醇、4.5重量份丙酮(作为溶剂)和0.03重量份催化剂二月桂酸二丁基锡(DBTDL)，将上述组分加入到反应装置中，在90-115℃下搅拌反应2h；然后向混合液中加入1.2重量份三乙胺进行中和反应30min，再加入64重量份去离子水进行乳化和1.2重量份乙二胺进行扩链，制得水性聚氨酯9乳液；然后向上述组分中加入0.05重量份二氧化硅气凝胶10粉末，在常温常压下搅拌20min后，得到二氧化硅气凝胶/水性聚氨酯体系，平铺在模具中，待其呈不流动状态时，等距填充0.01重量份的支撑组件11和0.01重量份的减震组件12，完全固化后形成聚氨酯弹性体层5；
(3)、将吸音层4(第一声屏障)、聚氨酯弹性体层5和隔音层6(第二声屏障)粘结成整体组成复合层；
(4)、拼接各部分并填充：依次将上基层1、硬质泡沫层3、复合层和下基层8通过胶黏剂粘结或热压形成具有高硬度、抗形变、吸引效果优异，同时具有一定隔热、阻燃作用的建筑材料。
其中，步骤(4)中，胶黏剂由树脂与固化剂组成，树脂可以是热塑型树脂(纤维素酯、烯类聚合物、聚酯、聚醚、聚酰胺等)或热固性树脂(环氧树脂、酚醛树脂、脲醛树脂、有机硅树脂等)，固化剂可以是脂肪族胺类(乙烯基三胺、二氨基环己烷、二乙烯三胺等)、芳族胺类(间苯二胺、间苯二甲胺、间氨基甲胺等)、酰胺基胺类、潜伏固化胺类等，树脂与固化剂的质量比为100：4。
上述对具体实施方式的描述是为了便于该技术领域的普通技术人员能理解和使用本发明。熟悉本领域技术人员显然可以容易的对这些具体实施方式做出各种修改，并把在此说明的一般原理应用到其他实施方式中，而不必经过创造性的劳动。因此，本发明不限于上述具体实施方式。本领域技术人员根据本发明的原理，不脱离本发明的范畴所做出的改进和修改都应该在本发明的保护范围之内。

Claims (10)

1.一种具有隔音功能的建筑材料，其特征在于：其从上至下依次包括上基层(1)、硬质泡沫层(3)、复合层和下基层(8)；
所述复合层由吸音层(4)、聚氨酯弹性体层(5)和隔音层(6)组成，所述聚氨酯弹性体层(5)位于吸音层(4)和隔音层(6)之间，所述聚氨酯弹性体层(5)包括水性聚氨酯(9)、二氧化硅气凝胶(10)、支撑组件(11)和减震组件(12)，所述二氧化硅气凝胶(10)分散在水性聚氨酯(9)中，所述支撑组件(11)和减震组件(12)垂直等距分散在水性聚氨酯(9)和二氧化硅气凝胶(10)之间。
2.根据权利要求1所述的具有隔音功能的建筑材料，其特征在于：所述聚氨酯弹性体层(5)的制备过程：将二异氰酸酯、二元醇、丙酮和二月桂酸二丁基锡混合反应，得到混合液；在所述混合液中加入三乙胺进行中和反应，之后加入去离子水和乙二胺得到水性聚氨酯乳液；在所述水性聚氨酯(9)乳液中加入二氧化硅气凝胶(10)，得到二氧化硅气凝胶/水性聚氨酯体系；在所述二氧化硅气凝胶/水性聚氨酯体系中加入支撑组件(11)和减震组件(12)，常温下固化即可；
优选地，二异氰酸酯选自异佛尔酮二异氰酸酯、甲苯二异氰酸酯、二苯基甲烷二异氰酸酯、二环己基甲烷二异氰酸酯或六亚甲基二异氰酸酯中的一种以上；
优选地，二元醇选自聚己内酯二醇、聚碳酸酯二元醇、聚己二酸丁二醇酯、聚丙二醇或聚硅氧烷二醇中的一种以上。
3.根据权利要求2所述的具有隔音功能的建筑材料，其特征在于：所述支撑组件(11)选自钢管、H型钢、角钢或硬质塑料中的一种以上。
4.根据权利要求2所述的具有隔音功能的建筑材料，其特征在于：所述减震组件(12)选自弹簧、橡胶或弹簧钢中的一种以上。
5.根据权利要求1所述的具有隔音功能的建筑材料，其特征在于：所述吸音层(4)选自木质吸音板、矿棉吸音板或布艺吸音板中的一种以上，所述吸音层(4)的厚度为0.1-0.15cm。
6.根据权利要求1所述的具有隔音功能的建筑材料，其特征在于：所述隔音层(6)选自隔音棉或隔音板中的一种以上，所述隔音层(6)的厚度为0.1-0.15cm。
7.根据权利要求1所述的具有隔音功能的建筑材料，其特征在于：所述硬质泡沫层(3)选自聚氨酯塑料泡沫板、硅酸铝纤维板或聚乙烯泡沫塑料中的一种以上，所述硬质泡沫层(3)的厚度为0.05-0.1cm。
8.根据权利要求1所述的具有隔音功能的建筑材料，其特征在于：所述上基层(1)选自木质基材、塑料基材或铝合金基材中的一种以上；和/或，
所述下基层(8)选自刚性的木质基材、铝合金基材、塑钢、石膏板或硬质纤维板中的一种以上，所述下基层(8)的厚度为0.15-0.2cm；和/或，
所述刚性的木质基材选自细木工板、三聚氰胺板、木塑板或三合板中的一种以上；和/或，
所述具有隔音功能的建筑材料还包括上支撑层(2)和下支撑层(7)，所述上支撑层(2)紧贴上基层(1)和硬质泡沫层(3)之间，所述下支撑层(7)紧贴复合层和下基层(8)之间；所述上支撑层(2)和下支撑层(7)均选自玻璃纤维网或烧结金属网中的一种以上。
9.一种根据权利要求1-8任一项所述的具有隔音功能的建筑材料的制备方法，其特征在于：其包括如下步骤：
(1)、制备上基材：在上基层(1)的内侧平铺硬质泡沫层(3)，通过胶合的方式连接在一起；
(2)、制备聚氨酯弹性体层(5)：将二异氰酸酯、二元醇、丙酮和二月桂酸二丁基锡混合反应，得到混合液；在所述混合液中加入三乙胺进行中和反应，之后加入去离子水和乙二胺得到水性聚氨酯乳液；在所述水性聚氨酯(9)乳液中加入二氧化硅气凝胶(10)，得到二氧化硅气凝胶/水性聚氨酯体系；在所述二氧化硅气凝胶/水性聚氨酯体系中加入支撑组件(11)和减震组件(12)，常温下固化即可；
(3)、制备复合层：将吸音层(4)、聚氨酯弹性体层(5)和隔音层(6)粘结在一起；
(4)、将上基层(1)、硬质泡沫层(3)、复合层和下基层(8)通过粘结的形式复合，得到具有隔音功能的建筑材料。
10.根据权利要求9所述的制备方法，其特征在于：步骤(1)中，所述上基层(1)选自木质基材、塑料基材或铝合金基材中的一种以上；和/或，
步骤(1)中，所述硬质泡沫层(3)选自聚氨酯塑料泡沫板、硅酸铝纤维板或聚乙烯泡沫塑料中的一种以上；和/或，
步骤(2)中，所述支撑组件(11)选自钢管、H型钢、角钢或硬质塑料中的一种以上；和/或，
步骤(2)中，所述减震组件(12)选自弹簧、橡胶或弹簧钢中的一种以上；和/或，
步骤(3)中，所述吸音层(4)选自木质吸音板、矿棉吸音板或布艺吸音板中的一种以上；和/或，
步骤(3)中，所述隔音层(6)选自隔音棉或隔音板中的一种以上；和/或，
步骤(4)中，所述下基层(8)选自刚性的木质基材、铝合金基材、塑钢、石膏板或硬质纤维板中的一种以上。
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