CN116423927A - 一种蜂窝夹芯复合结构的隔音板及其制造方法 - Google Patents

一种蜂窝夹芯复合结构的隔音板及其制造方法 Download PDF

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CN116423927A
CN116423927A CN202310416418.XA CN202310416418A CN116423927A CN 116423927 A CN116423927 A CN 116423927A CN 202310416418 A CN202310416418 A CN 202310416418A CN 116423927 A CN116423927 A CN 116423927A
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honeycomb
sound insulation
damping material
board
bionic
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郝景新
左智兴
吴新凤
徐大鹏
余禹昕
龙彩凤
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Central South University of Forestry and Technology
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Central South University of Forestry and Technology
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Abstract

本发明公开了一种蜂窝夹芯复合结构的隔音板，包括表板和隔音芯层，其特征在于，所述隔音芯层包括至少一层仿生蜂窝结构或两层仿生蜂窝结构中间夹一层间隔板；仿生蜂窝孔腔内填充阻尼材料或仿生蜂窝胞壁上浸涂隔音阻尼材料。仿生蜂窝孔腔内填充的隔音阻尼材料为固体阻尼材料或融熔状阻尼材料；仿生蜂窝胞壁上浸涂的隔音阻尼材料为液体阻尼材料；其制造工艺分为填充型隔音板生产工艺和浸涂型隔音板生产工艺。经过实验表明，蜂窝夹芯复合结构的隔音板隔声性能好于同厚度的其它结构板，且具有密度低、轻质高强、耐火阻燃特性，满足工厂预制化、定制化生产模式。

Description

一种蜂窝夹芯复合结构的隔音板及其制造方法
技术领域
本发明涉及建筑制品的声学领域，具体为一种蜂窝夹芯复合结构的隔音板及其制造方法。
背景技术
居住区的集中和噪声污染源的激增，以及两者不可调和矛盾的日益激化，催生了市场对静音木门、建筑静音墙体等产品的强劲需求。尤其在一些特殊的公共领域，如商业建筑、电视台、医院、电影院、KTV和高档酒店等，对噪音管制的要求更是有明确规定的标准。静音木门、静音墙体等成为中高端市场的新宠，预计潜在市场规模达数万亿元。
现有的隔音产品多采用龙骨骨架内填充隔音棉、泡沫板等材料组成芯层，芯层表面粘帖木质材料薄板，这种结构方式需耗费大量的组装所需的人力和时间，生产效率低，不适合装配式、定制化生产，况且泡沫板等材料难以降解、污染环境。同时，作为主流产品的蜂窝夹芯木门、蜂窝夹芯墙体虽然具用轻质高强的特点，但隔音效果比较差。因此开发环保、轻质，适合装配式、定制化生产的隔音产品是实现建筑与家居产业高质量发展的客观要求。
发明内容
为了克服现有的产品易噪音穿透，控制能力弱的不足，不适合装配式、定制化生产的弊端，本发明在构筑仿生蜂窝“孔洞结构”的基础上，通过仿生蜂窝胞壁浸涂或腔体填充隔音阻尼材料的思路，提出了一种蜂窝夹芯复合结构的隔音板及其制造方法。为实现解决上述技术问题，本发明采用如下技术方案：
一种蜂窝夹芯复合结构的隔音板，包括表板和隔音芯层，其特征在于，所述隔音芯层包括至少一层仿生蜂窝结构或两层仿生蜂窝结构中间夹一层间隔板；仿生蜂窝孔腔内填充阻尼材料或仿生蜂窝胞壁上浸涂阻尼材料。仿生蜂窝孔腔内填充的隔音阻尼材料为固体阻尼材料或融熔状阻尼材料；仿生蜂窝胞壁上浸涂的隔音阻尼材料为液体阻尼材料。所述固体阻尼材料为颗粒状、片状、块状或其混合状，类别为橡胶、聚乙烯、聚丙烯、硅藻泥、红橡胶、聚氨酯或其它高分子类隔音阻尼材料；融熔状阻尼材料为橡胶、聚乙烯、聚丙烯、硅藻泥、红橡胶、聚氨酯或其它高分子类隔音阻尼材料；液体阻尼材料为橡胶、聚乙烯、聚丙烯、硅藻泥、红橡胶、聚氨酯固体阻尼材料分散于溶剂中的混合悬浮溶液、涂料类阻尼材料或其它液体高分子隔音阻尼材料。经过实验表明，所述蜂窝夹芯复合结构的隔音板隔声性能强于同等厚度的无隔音芯层板以及纸蜂窝隔音芯层板材。
作为对上述技术方案的进一步改进：
(1)所述间隔板为橡胶板、隔音棉、薄型纤维材料板、塑料板或铝板，厚度为0.2-2.5mm。
(2)所述表板为木基人造饰面板、金属板或塑料板；所述仿生蜂窝为六边形蜂窝、棱形蜂窝、瓦楞型蜂窝或其它薄壁空腔结构。
(3)所述仿生蜂窝厚度为6-200mm，孔径为2-9mm，壁厚在0.1-0.4mm。
(4)所述表板与隔音芯层之间使用胶粘接；隔音芯层的各层之间使用胶粘接，或不使用胶。
一种蜂窝夹芯复合结构的隔音板的制造方法，其特征在于：包括以下步骤：
制造工艺分为填充型隔音板生产工艺和浸涂型隔音板生产工艺，其中填充型隔音板生产工艺包括：
S1：将仿生蜂窝拉伸至2440×1220mm或所需板件尺寸大小；
S2：将一张表板的单侧涂胶面打磨，将胶粘剂均匀的涂覆在表板的涂胶面，再将S1所述拉伸的仿生蜂窝覆于表板上；
S3：将S2处理好仿生蜂窝孔内填充所述阻尼材料中的一种固态颗粒，随后覆盖一层间隔板，间隔板双面均匀涂覆胶粘剂；
S4：将与S1拉伸同样尺寸的另一仿生蜂窝覆盖于S3所述的间隔板之上，再填充同样的阻尼材料颗粒，最后将另外一张表板涂覆胶粘剂后覆盖其上，施压，固化，最终形成五层结构的蜂窝夹芯复合结构的隔音板；
浸涂型隔音板生产工艺包括：
S1：先将仿生蜂窝拉伸至2440×1220mm或所需板件尺寸大小；
S2：将S1拉伸的仿生蜂窝浸入所述阻尼材料的液体中，使所述仿生蜂窝各面浸充分但不完全封孔；
S3：将已浸涂后的仿生蜂窝取出晾干或加热烘干；
S4：将一张表板的单侧涂胶面打磨，将胶粘剂均匀的涂覆在表板的涂胶面，再将S3所述浸涂后仿生蜂窝覆于表板上，随后覆盖一层间隔板，间隔板双面均匀涂覆胶粘剂；
S5：将S3所述同样浸涂阻尼材料的仿生蜂窝覆盖于S4所述的间隔板(202)之上，最后将另一张表板涂覆胶粘剂后覆盖其上，施压，固化，最终形成五层结构的蜂窝夹芯复合结构的间隔板；
与现有技术相比，本技术的优点在于：
经过实验表明，本发明中的蜂窝夹芯复合结构的隔音板，相对于无填充阻尼材料的铝蜂窝隔音板，以及纸蜂窝隔音芯层板材隔声性能显著提高；表板可以替换成强度更高或防水性能更好的材料以适应不同的应用场景。本发明提出的蜂窝夹芯复合结构的隔音板具有密度低、轻质高强、耐火阻燃特性；此外，仿生蜂窝与表板先复合成1220×2440mm的标准大板，再根据顾客的需求裁切成不同规格的小板，满足隔音板的工厂预制化生产、定制化生产模式。
附图说明：
图1是实施例1中填充橡胶颗粒的蜂窝夹芯隔音板五层结构示意图。
图2是实施例4中浸涂聚氨脂的蜂窝夹芯隔音板五层结构示意图。
图3是实施例7中浸涂红橡胶的蜂窝夹芯隔音门板五层结构示意图。
图4是实施例8中浸涂硅藻泥的蜂窝夹心隔音板三层结构示意图。
图中各标号表示：
1、表板；2、隔音芯层；201、仿生蜂窝；202、间隔板；203、阻尼材料；3、框架
具体实施方式
以下将结合说明书附图和具体实施对本发明做进一步详细说明。
特点用图文展示
实施例1：(橡胶颗粒填充、边5铝蜂窝夹芯板)
本实施例中，图1示出一种蜂窝填充橡胶颗粒的夹芯复合结构的隔音板及其制造方法。蜂窝填充夹芯复合结构的隔音板包括表板和隔音芯层，表板为5mm厚中密度纤维板，隔音芯层为22mm厚。隔音芯层由两层边为5mm、厚为10mm铝蜂窝填充阻尼材料结构中间夹一层间隔板；所述间隔板为2mm橡胶板，所述阻尼材料为直径为4mm的橡胶颗粒，使橡胶颗粒均匀填充于第一层铝蜂窝板每一个孔内后，覆盖涂胶的2mm橡胶板，再将第二层相同尺寸的铝蜂窝板覆盖，再使橡胶颗粒均匀填充于第二层铝蜂窝每一个孔内后，最后覆盖5mm中密度纤维表板。所述表板、隔音芯层和隔音芯层各层之间使用AB胶粘接而成，施压固化后即可得到蜂窝夹芯复合结构填充橡胶颗粒的隔音板。
实施例2：(聚丙烯颗粒填充、边5铝蜂窝夹芯板)
按照实施例1所述的方法和结构制备铝蜂窝夹芯复合结构的隔音板，不同的是，所述阻尼材料为聚丙烯颗粒。
实施例3：(聚乙烯颗粒填充、边5铝蜂窝夹芯板)
按照实施例1所述的方法和结构制备铝蜂窝夹芯复合结构的隔音板，不同的是，本实施例中所述阻尼材料为聚乙烯颗粒。
实施例4：(浸聚氨酯、边5铝蜂窝夹芯板)
本实施例中，图2示出一种蜂窝浸聚氨酯的夹芯复合结构的隔音板及其制造方法。蜂窝浸制夹芯复合结构的隔音板包括表板和隔音芯层。表板为5mm的胶合板，隔音芯层为22mm厚。隔音芯层由一层间隔板上下覆面两层浸涂阻尼材料的铝蜂窝板结构；铝蜂窝板边为5mm、厚为10mm，所述间隔板为2mm橡胶板，所述阻尼材料为固含量95％以上的聚氨酯涂料，使两层铝蜂窝板(201)充分浸入聚氨酯涂料中但不完全填满铝蜂窝的孔径，风干。间隔板两面胶接浸聚氨酯的蜂窝板形成隔音芯层。芯层嵌入上下表板即可得到蜂窝夹芯复合结构浸制聚氨酯的隔音板，所述表板、隔音芯层和隔音芯层各层之间使用AB胶粘接而成。
实施例5：(浸红橡胶、边5铝蜂窝夹芯板)
按照实施例4所述的方法和结构制备夹芯复合结构的隔音板，不同的是，本实施例中所述阻尼材料为浓度50％的红橡胶涂料。
实施例6：(浸硅藻泥、边5铝蜂窝夹芯板)
按照实施例4所述的方法和结构制备夹芯复合结构的隔音板，不同的是，本实施例中所述阻尼材料为浓度60％的硅藻泥涂料。
实施例7：(隔音木门、浸红橡胶)
本实施例中，图3示出一种蜂窝浸红橡胶涂料的夹芯复合结构的隔音门板。蜂窝浸制的夹芯复合结构的隔音门板包括表板、隔音芯层和门框架。表板为人造板，隔音芯层由一层间隔板上下覆面两层浸有阻尼材料的铝蜂窝板结构，铝蜂窝板边为5mm、厚为10mm；间隔板为2mm橡胶板，阻尼材料为浓度50％的红橡胶涂料，使两层铝蜂窝板充分浸入红橡胶涂料中且不完全填满铝蜂窝的孔径，风干。间隔板两面胶接浸涂红橡胶的蜂窝板形成隔音芯层，表板与框架内嵌入隔音芯层即可得到蜂窝夹芯复合结构浸制聚氨酯的隔音门板。
实施例8：(3层夹芯板、浸硅藻泥)
本实施例中，图4示出一种蜂窝浸硅藻泥涂料的三层夹芯结构的隔音板。蜂窝浸制夹芯三层结构的隔音板包括表板、隔音芯层。表板为5mm人造板，隔音芯层为一层铝蜂窝板浸染硅藻泥阻尼材料结构。铝蜂窝板为边长5mm铝蜂窝，厚度为10mm。所述阻尼材料为浓度60％的硅藻泥涂料，使铝蜂窝板充分浸入硅藻泥涂料中且不完全填满铝蜂窝的孔径，风干。两层表板之间嵌入浸有硅藻泥涂料铝蜂窝板的隔音芯层即可得到三层蜂窝夹芯复合结构浸制硅藻泥涂料的隔音板。
实施例9：(隔音墙板，浸硅藻泥)
本实施例中，示出一种蜂窝浸硅藻泥涂料的夹芯复合结构的隔音墙板，包括表板、隔音芯层。表板为5mm的竹制板，隔音芯层为一层厚度为90mm的铝蜂窝板浸制阻尼材料结构。铝蜂窝板边长为5mm，所述阻尼材料为浓度60％的硅藻泥涂料，使铝蜂窝板充分浸入硅藻泥涂料中且不完全填满铝蜂窝的孔径，风干。两层表板之间嵌入浸有硅藻泥涂料铝蜂窝板的隔音芯层即施压固化后即为100mm厚三层蜂窝夹芯复合结构浸制硅藻泥涂料的隔音墙板。
对比例1：(未处理的铝蜂窝夹芯板)
未填充或浸涂阻尼材料的铝蜂窝夹芯板，整体板厚为32mm，其中表板为5mm厚中密度纤维板，芯层为22mm厚的复合结构；芯层由两层边为5mm、厚为10mm铝蜂窝结构中间夹一层2mm的橡胶板。
对比例2：(纸蜂窝夹芯板)
纸蜂窝夹芯板，整体板厚为35mm，共三层结构，其中表板为5mm厚中密度纤维板，芯层为25mm厚纸蜂窝芯层。
性能测试
按照国标GB/T 50121-2005建筑隔声评价标准进行计权隔声量的测定。
上述实施例1-6制备的不同蜂窝夹芯复合结构的隔音板及对比例1-2的复合材料的隔声性能(计权隔声量)测定结果如表1所示。
表1
Figure BDA0004185186410000051
Figure BDA0004185186410000061
从表1的结果可以看出，填充阻尼材料的铝蜂窝夹芯复合结构的隔音板比未处理的同厚度铝蜂窝夹芯板的隔声性能高6.4-7.3dB，浸涂阻尼材料的铝蜂窝夹芯复合结构的隔音板比未处理的同厚度铝蜂窝夹芯板的隔声性能高5.0-7.4dB；本发明提出的填充或浸涂阻尼材料的铝蜂窝夹芯复合结构的隔音板的隔声性能显著好于纸蜂窝夹芯板。

Claims (8)

1.一种蜂窝夹芯复合结构的隔音板，包括表板(1)和隔音芯层(2)，其特征在于，所述隔音芯层(2)至少一层仿生蜂窝(201)结构或两层仿生蜂窝(201)结构中间夹一层间隔板(202)；仿生蜂窝(201)孔腔内填充阻尼材料(203)或仿生蜂窝(201)胞壁上浸涂阻尼材料(203)。
2.根据权利要求1所述一种蜂窝夹芯复合结构的隔音板，其特征在于：仿生蜂窝(201)孔腔内填充的隔音阻尼材料(203)为固体阻尼材料或融熔状阻尼材料，固体阻尼材料为颗粒状、片状、块状或其混合状；仿生蜂窝(201)胞壁上浸涂的隔音阻尼材料(203)为液体阻尼材料，液体阻尼材料的隔音阻尼成份占液体总质量的比例为30-90％。
3.根据权利要求2所述一种蜂窝夹芯复合结构的隔音板，其特征在于：所述固体阻尼材料为橡胶、聚乙烯、聚丙烯、硅藻泥、红橡胶、聚氨酯或其它高分子类隔音阻尼材料；融熔状阻尼材料为橡胶、聚乙烯、聚丙烯、硅藻泥、红橡胶、聚氨酯或其它高分子类隔音阻尼材料；液体阻尼材料为橡胶、聚乙烯、聚丙烯、硅藻泥、红橡胶、聚氨酯固体阻尼材料分散于溶剂中的混合悬浮溶液、涂料类阻尼材料或其它液体高分子隔音阻尼材料。
4.根据权利要求1所述一种蜂窝夹芯复合结构的隔音板，其特征在于：所述间隔板(202)为橡胶板、隔音棉、薄型人造板、塑料板或铝板，厚度为0.2-2.5mm。
5.根据权利要求1所述一种蜂窝夹芯复合结构的隔音板，其特征在于：所述表板(1)为木基饰面板、实木板、竹材板、金属板或塑料板；所述仿生蜂窝(201)为六边形蜂窝、棱形蜂窝、瓦楞型蜂窝或其它薄壁空腔结构。
6.根据权利要求1所述一种蜂窝夹芯复合结构的隔音板，其特征在于所述仿生蜂窝(201)厚度为6-200mm，孔径为2-9mm，壁厚在0.1-0.4mm。
7.根据权利要求1所述一种蜂窝夹芯复合结构的隔音板，其特征在于：所述表板(1)与隔音芯层(2)之间使用胶粘接；隔音芯层(2)的各层之间使用胶粘接，或不使用胶。
8.一种蜂窝夹芯复合结构的隔音板的制造方法，其特征在于：包括以下步骤：
制造工艺分为填充型隔音板生产工艺和浸涂型隔音板生产工艺，其中填充型隔音板生产工艺包括：
S1：将仿生蜂窝(201)拉伸至2440×1220mm或所需板件尺寸大小；
S2：将一张表板(1)的单侧涂胶面打磨，将胶粘剂均匀的涂覆在表板(1)的涂胶面，再将S1所述拉伸的仿生蜂窝覆于表板上；
S3：将S2处理好仿生蜂窝孔内填充所述阻尼材料(203)中的一种固态颗粒，随后覆盖一层间隔板(202)，间隔板双面均匀涂覆胶粘剂；
S4：将与S1拉伸同样尺寸的另一仿生蜂窝覆盖于S3所述的间隔板(202)之上，再填充同样的阻尼材料(203)颗粒，最后将另外一张表板(1)涂覆胶粘剂后覆盖其上，施压，固化，最终形成五层结构的蜂窝夹芯复合结构的隔音板；
浸涂型隔音板生产工艺包括：
S1：先将仿生蜂窝(201)拉伸至2440×1220mm或所需板件尺寸大小；
S2：将S1拉伸的仿生蜂窝(201)浸入所述阻尼材料(203)的液体中，使所述仿生蜂窝(201)各面浸充分但不完全封孔；
S3：将已浸涂后的仿生蜂窝(201)取出晾干或加热烘干；
S4：将一张表板(1)的单侧涂胶面打磨，将胶粘剂均匀的涂覆在表板(1)的涂胶面，再将S3所述浸涂后仿生蜂窝(201)覆于表板上，随后覆盖一层间隔板(202)，间隔板双面均匀涂覆胶粘剂；
S5：将S3所述同样浸涂阻尼材料的仿生蜂窝(201)覆盖于S4所述的间隔板(202)之上，最后将另一张表板(1)涂覆胶粘剂后覆盖其上，施压，固化，最终形成五层结构的蜂窝夹芯复合结构的隔音板。
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