CN114987001A

CN114987001A - Hard open-cell foam sound insulation board and preparation method and application thereof

Info

Publication number: CN114987001A
Application number: CN202210833835.XA
Authority: CN
Inventors: 戢超; 池佩富; 罗亿江
Original assignee: Fujian Ten Lead Advanced Material Co ltd
Current assignee: Fujian Ten Lead Advanced Material Co ltd
Priority date: 2022-07-14
Filing date: 2022-07-14
Publication date: 2022-09-02

Abstract

The invention relates to the field of building materials, in particular to a hard open-cell foam sound insulation board and a preparation method and application thereof. Wherein, the rigid open-cell foam sound insulation board is obtained by directly compounding rigid open-cell foam with a cement-based coiled material; the hard open-cell foam is mainly prepared by blending and modifying benzoxazine resin and phenolic resin. The hard open-cell foam sound insulation board provided by the invention is modified by blending the phenolic resin and the benzoxazine resin, has good fireproof performance and high toughness and compressive strength, and has a good effect of eliminating floor impact noise and air noise.

Description

Hard open-cell foam sound insulation board and preparation method and application thereof

Technical Field

The invention relates to the field of building materials, in particular to a hard open-cell foam sound insulation board and a preparation method and application thereof.

Background

At present, the floor sound insulation in the building material mainly takes polyethylene or polyurethane soft foam as a main material, the polyethylene or polyurethane soft foam is made of soft materials, and after concrete and the floor are paved on the soft foam, people walk on the soft foam, so that the quality problem that the floor is hollowly constructed by mistake is easily caused. And the polyethylene or polyurethane soft foam generally takes closed cells as the main principle of sound insulation, and the main principle of sound insulation is that the frequency of sound transmission is changed by the cavity resonance effect generated when an object impacts the floor, so that the reflection times are reduced, and impact noise is effectively isolated. Such closed cell foams do not provide effective cancellation of air noise (noise generated by non-floor impacts). In addition, the fireproof grade of the polyethylene or polyurethane soft foam is B3-B1, and the construction process has certain fire hazard.

For example, patent document CN109262937A, published as 2019, 01, 25 discloses a method for manufacturing a polyurethane sound insulation board, which comprises the following steps: manufacturing a polyurethane sound insulation board by using a polyurethane raw material produced by a polyurethane foaming machine; punching holes with the diameter of 0.001-0.01 mm on the polyurethane sound insulation board by using stainless steel capillary laser punching equipment; the polyurethane sound insulation board is provided with the reinforcing ribs, so that the vibration of the sound insulation board is reduced; the polyurethane block is embedded in the polyurethane sound-insulating board to destroy the resonance of the polyurethane sound-insulating board.

Above-mentioned scheme has strengthened the syllable-dividing and the intensity performance of polyurethane acoustic celotex board to a certain extent, but the preparation process is comparatively complicated, and manufacturing cost is high. Meanwhile, the problems of mistaken recognition of empty bulging and poor air noise isolation cannot be solved, and meanwhile, the fireproof performance is not improved.

Disclosure of Invention

In order to solve the problems of floor hollowing, poor air noise insulation and insufficient fireproof performance which are mistakenly recognized in the prior art, the invention provides the hard open-cell foam sound insulation board which is obtained by directly compounding the hard open-cell foam with the cement-based coiled material; the hard open-cell foam is mainly prepared by blending and modifying benzoxazine resin and phenolic resin.

In one embodiment, the benzoxazine resin is a benzo-fused ring compound containing a nitrogen-oxygen six-membered heterocyclic ring, and the phenolic resin is a thermosetting phenolic resin.

In one embodiment, the components further comprise a foaming agent, an emulsifier, a cell opener and a curing agent.

In one embodiment, the blowing agent is one or a combination of cyclopentane, n-pentane, and isopentane.

In one embodiment, the emulsifier is EL-30.

In one embodiment, the cell opener is one or a mixture of sodium dodecyl benzene sulfonate and detergent.

In one embodiment, the curing agent is one or more of oxalic acid, phenolsulfonic acid, phosphoric acid, p-toluenesulfonic acid.

In one embodiment, the rigid open-cell foam comprises the following components in parts by mass:

in one embodiment, the compressive strength is 0.2 to 1 MPa.

In one embodiment, the cement-based web is made primarily of fiberglass filaments or meshes, and cement, fine sand, polymer emulsions.

In one embodiment, the thickness of the surface layer is 0.05-2 mm.

In one embodiment, the overall thickness is 3-50 mm.

In one embodiment, the compounding process is an online compounding process: placing a lower cement-based coiled material on a lower unreeling frame at the front end part of the production line, placing an upper cement-based coiled material on an upper unreeling frame, pouring a phenolic aldehyde foaming material liquid between two plates at the head part of a laminating machine, and entering the laminating machine for starting, curing and forming; the phenolic foaming liquid is prepared by stirring uniformly benzoxazine resin, phenolic resin, foaming agent, emulsifier and pore-forming agent in advance, conveying the mixture to a pouring head through a pipeline, and quickly stirring the mixture uniformly with a curing agent conveyed by another pipeline.

The invention also provides a preparation method for preparing the hard open-cell foam sound insulation board, which comprises the following steps:

s100, adding benzoxazine resin, phenolic resin, foaming agent, emulsifier and pore-forming agent into a stirring tank (A material tank) and uniformly stirring

S200, pouring the prepared curing agent into a curing agent tank (B material tank).

S300, placing the lower-layer cement-based coiled material on the lower-layer unwinding frame at the front end of the assembly line and placing the upper-layer cement-based coiled material on the upper-layer unwinding frame at the front end of the assembly line

S400, raising the temperature of the drying room to 60-75 ℃ in advance.

S500, pumping the feed liquid of the A/B material tank to a pouring head, quickly stirring, pouring the feed liquid between the two plates, and entering a laminating machine for starting, curing and forming.

The invention also provides application of the rigid open-cell foam sound insulation board in the field of buildings.

Based on the above, the hard open-cell foam sound insulation board provided by the invention has the following beneficial effects:

1. the hard open-cell foam adopted by the invention is a porous material, when sound waves are projected to the surface of the porous material, a part of the sound waves are reflected, and a part of the sound waves are thrown into the porous material. The penetrated sound wave can excite the air molecules and the skeleton in the material foam pores to vibrate, and the air expands and compresses due to the viscosity among the air molecules and the friction between the air and the skeleton, so that the heat exchange is continuously carried out between the air and the skeleton, the energy of the sound wave is converted into heat energy to be lost, and the sound insulation function is further realized. The invention has good effect of eliminating floor impact noise and air noise.

2. The invention uses the hard open-cell foam material, the whole structure is a sandwich structure, and no 'hollow drum' sound is generated. Meanwhile, the compressive strength can reach 0.2-1 Mpa, and the method can be suitable for application in various scenes.

3. The invention uses benzoxazine resin and phenolic resin as core layers, so that the fireproof performance of the rigid open-cell foam sound insulation board reaches A level, and the fire hazard is avoided.

4. Compared with the common phenolic foam, the benzoxazine resin and the phenolic resin are blended and modified, so that the toughness of the hard open-cell foam material is improved, the hard open-cell foam material is not easy to fall off, and the service life of the product is prolonged.

Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the embodiments or the description in the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts; in the following description, the drawings are illustrated in a schematic view, and the drawings are not intended to limit the present invention.

Fig. 1 is a structural diagram of an embodiment of a rigid open-cell foam sound-insulating panel according to the present invention.

Reference numerals:

1 core layer 2 face layers

Detailed Description

In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some embodiments of the present invention, but not all embodiments; the technical features designed in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other; all other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

In the description of the present invention, it is to be noted that all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present invention belongs, and are not to be construed as limiting the present invention; it will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

Example 1

S100, adding 10 parts of benzoxazine resin, 100 parts of phenolic resin, 5 parts of foaming agent, 2 parts of emulsifier and 4 parts of pore-forming agent into a stirring tank (A material tank) and uniformly stirring.

S200, pouring 18 parts of prepared curing agent into a curing agent tank (B material tank).

S300, placing the lower-layer cement-based coiled material on the lower-layer unwinding frame and placing the upper-layer cement-based coiled material on the upper-layer unwinding frame at the front end of the assembly line.

S400, raising the temperature of the drying room to 60 ℃ in advance.

The surface layer thickness is 0.05mm, and the whole thickness is 3 mm.

Example 2

S100, adding 20 parts of benzoxazine resin, 100 parts of phenolic resin, 7 parts of foaming agent, 4 parts of emulsifier and 7 parts of pore-forming agent into a stirring tank (A material tank) and uniformly stirring.

S200, pouring 25 parts of the prepared curing agent into a curing agent tank (B material tank).

S400, raising the temperature of the drying room to 65 ℃ in advance.

The surface layer thickness is 0.05mm, and the whole thickness is 3 mm.

Example 3

S100, adding 30 parts of benzoxazine resin, 100 parts of phenolic resin, 10 parts of foaming agent, 6 parts of emulsifier and 9 parts of pore-forming agent into a stirring tank (A material tank) and uniformly stirring.

S200, pouring 35 parts of prepared curing agent into a curing agent tank (B material tank).

S400, raising the temperature of the drying room to 75 ℃ in advance.

The surface layer thickness is 0.05mm, and the whole thickness is 3 mm.

Example 4

S100, adding 20 parts of benzoxazine resin, 100 parts of phenolic resin, 5 parts of foaming agent, 2 parts of emulsifier and 4 parts of pore-forming agent into a stirring tank (A material tank) and uniformly stirring.

S400, raising the temperature of the drying room to 60 ℃ in advance.

The surface layer thickness is 1mm, and the whole thickness is 10 mm.

Example 5

S100, adding 35 parts of benzoxazine resin, 100 parts of phenolic resin, 10 parts of foaming agent, 2 parts of emulsifier and 4 parts of pore-forming agent into a stirring tank (A material tank) and uniformly stirring.

S300, placing the lower-layer cement-based coiled material on the lower-layer unwinding frame at the front end of the assembly line and placing the upper-layer cement-based coiled material on the upper-layer unwinding frame at the front end of the assembly line.

S400, raising the temperature of the drying room to 60 ℃ in advance.

The surface layer thickness is 2mm, and the whole thickness is 50 mm.

Comparative example 1

The preparation method is the same as that of example 1, and 10 parts of benzoxazine resin is replaced by phenolic resin, namely 110 parts of phenolic resin is added. The surface layer thickness is 0.05mm, and the whole thickness is 3 mm.

Comparative example 2

The preparation method is the same as that of the embodiment 1, and the phenolic resin is completely replaced by the benzoxazine resin, namely 110 parts of the benzoxazine resin is added. The surface layer thickness is 0.05mm, and the whole thickness is 3 mm.

Comparative example 3

The preparation method is the same as that of the example 1, except that 50 parts of benzoxazine resin and 60 parts of phenolic resin are adopted. The surface layer thickness is 0.05mm, and the whole thickness is 3 mm.

Comparative example 4

The preparation method is the same as that of the embodiment 1, and is different in that the cement-based surface layer is not compounded, and the feed liquid is directly poured into a mold for foaming and molding. The overall thickness is 3 mm.

The sound insulation performance, the fire resistance performance, the toughness and the compressive strength of the samples of examples 1 to 6 and comparative examples 1 to 4 were measured, and the powder falling condition was observed. The test items and standards are shown in Table 1, and the test results are shown in Table 2.

TABLE 1 test items and standards

Sound insulation performance	GB50121
		Fire-proof performance	GB8624
Toughness (drawing strength)	GB20974
		Compressive strength	GB20974
Powder falling condition	Visually observing whether dust exists or not after touching

TABLE 2 test results

Compared with the prior art, the hard open-cell foam sound insulation board provided by the invention is modified by blending the phenolic resin and the benzoxazine resin, has good fireproof performance and high toughness and compressive strength, and has a good effect of eliminating floor impact noise and air noise.

In addition, it will be appreciated by those skilled in the art that, notwithstanding the many problems inherent in the prior art, each embodiment or solution of the present invention may be improved in one or more respects, without necessarily simultaneously solving all the technical problems inherent in the prior art or in the background art. It will be understood by those skilled in the art that nothing in a claim should be taken as a limitation on that claim.

Although terms such as benzoxazine resins, phenolic resins, blending and the like are used more often herein, the possibility of using other terms is not excluded. These terms are used merely to more conveniently describe and explain the nature of the present invention; they are to be construed as being without limitation to any additional limitations that may be imposed by the spirit of the present invention; the terms "first," "second," and the like in the description and in the claims, and in the drawings, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order.

Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and these modifications or substitutions do not depart from the spirit of the corresponding technical solutions of the embodiments of the present invention.

Claims

1. A kind of hard open-cell foam sound insulation board, characterized by: is obtained by directly compounding hard open-cell foam with a cement-based coiled material; the hard open-cell foam is mainly prepared by blending and modifying benzoxazine resin and phenolic resin.

2. The rigid open cell foam acoustical panel of claim 1, wherein: the benzoxazine resin is a benzo-fused ring compound containing a nitrogen-oxygen six-membered heterocyclic ring, and the phenolic resin is thermosetting phenolic resin.

3. The rigid open cell foam acoustical panel of claim 1, wherein: the components also comprise a foaming agent, an emulsifying agent, a cell opening agent and a curing agent.

4. The rigid open cell foam acoustical panel of claim 1, wherein: the foaming agent is one or a combination of cyclopentane, n-pentane and isopentane.

5. The rigid open cell foam acoustical panel of claim 1, wherein: the emulsifier is EL-30; the cell opener is one or a mixture of sodium dodecyl benzene sulfonate and detergent.

6. The rigid open cell foam acoustical panel of claim 1, wherein: the curing agent is one or more of oxalic acid, phenolsulfonic acid, phosphoric acid and p-toluenesulfonic acid.

7. The rigid open cell foam acoustical panel of claim 1, wherein: the weight parts of each component are as follows:

8. the rigid open cell foam acoustical panel of claim 1, wherein: the compressive strength is 0.2-1 Mpa.

9. A method for preparing the rigid open-cell foam sound-insulating panel according to any one of claims 1 to 8, characterized by comprising the steps of:

s100, adding benzoxazine resin, phenolic resin, a foaming agent, an emulsifier and a pore-forming agent into a stirring tank (A material tank) and uniformly stirring;

s200, pouring the prepared curing agent into a curing agent tank (B material tank);

s300, placing a lower cement-based coiled material on a lower unreeling frame and an upper cement-based coiled material on an upper unreeling frame at the front end of the assembly line;

s400, raising the temperature of the drying room to 60-75 ℃ in advance;

s500, pumping the material liquid of the A \ B material tank to a pouring head for rapid stirring, pouring the material liquid between two plates, entering a laminating machine for starting, curing and molding.

10. Use of the rigid open-cell foam sound-insulating panel according to any one of claims 1 to 8 or the rigid open-cell foam sound-insulating panel produced by the production process according to claim 9 in the construction field.