RU176933U1 - Soundproof gypsum modular construction - Google Patents

Abstract

Soundproof gypsum modular construction. The utility model relates to the field of construction, namely to gypsum modular constructions such as tongue-and-groove plates with enhanced soundproofing characteristics. Contains structural orientation elements made in the form of at least one ridge 4 and one open groove 5, parallel parallel plates 1 and 2 located on its opposite ends, made of gypsum binder, a sound-proof layer 3 located between them, made of fibrous material structures with open pores and channels, interacting with the plates 1, 2 on the corresponding mating surfaces 6 and 7, the elements of the connection of the soundproof layer 3 with adjacent external parallel plates 1, 2, made ie each in the form of continuous border strips 8 and 9, the width «h» of 0.01 to 0.5 the thickness of the sound-insulating layer formed by the hardened in the pores and channels along both mating surfaces 6, 7 of gypsum binder. The material of the soundproofing layer 3 is used: medium to high density basalt insulation, light chipboard, felt, fiberglass mat, lightweight MDF, and the orientation elements of the ridges 4 and grooves 5 can be located on opposite ends as external parallel plates 1, 2 and sound insulation layer 3. The device solves the technical problem associated with the need to improve the acoustic properties of the structure with a value of R satisfying the specified requirements of the customer, while lowering its cost by simplifying the connection of external parallel slabs with a soundproofing layer and also increasing the productivity of manufacturing by reducing the time of its manufacture. 3 s.p. f-ly, 5 ill.

Description

The utility model relates to the field of industrial and civil engineering, namely to gypsum modular structures with enhanced soundproofing characteristics such as acoustic blocks, panels, plates, etc. and is used for the construction of internal non-bearing partitions and walls in the premises of buildings and structures for various purposes with dry and normal humidity conditions of building structures.

The analysis of the existing state of the art in this area showed that it is known to use prefabricated modular structures based on mounting orientation elements in the form of, for example, grooves and ridges, the so-called tongue-and-groove gypsum boards (panels, blocks), for the construction of lightweight partition walls in buildings.

The tongue-and-groove constructions are generally flat in shape and include gypsum external plates and a soundproofing (acoustic) layer located between them, made of combinations of materials selected to provide suitable sound absorption while maintaining sufficient adhesion between the layers of gypsum and the internal material. Common materials currently used to form acoustic panels include mineral wool, fiberglass, foam perlite, clay, calcium sulfate hemihydrate, calcium sulfate dihydrate particles, calcium carbonate, fiber-coated paper, shredded waste paper, and binders, such as starch or latex. Most often, mineral wool is used, since it contributes to the creation of a porous fibrous structure, thus providing good sound-absorbing characteristics. The layers are preferably interconnected by means of glue, for example, acrylic, which improves the weighted average rate (R _w ) of sound attenuation, but adds weight to the product and complicates the manufacturing process, for example, a laminated soundproof panel according to RF Patent for invention No. 2536549, IPC: E04B 1 / 86, B23B 7/12, publ. 04/27/2013, bull. No. 11.

A sound-insulating fence containing tongue-and-groove gypsum boards is known (RF Patent PM PM No. 155100, IPC: E04B 1/74, E04B 2/76, publ. September 20, 2015 Bull. No. 26).

The impossibility of achieving the result indicated by the claimed design by the indicated technical solution is caused by the fact that in the analogue construction the soundproofing properties are improved by attaching to the tongue-and-groove gypsum boards an external cladding of hard gypsum fiber sheet through a layer of elastic fiber material made of polyester fiber, which increases the cost of construction and complicates the conditions for its installation.

Known soundproofing panel for partitions, containing elements of its orientation, located at its ends, and made in the form of grooves and protrusions, external parallel plates and a soundproofing layer located between them, interacting with each other on a corresponding mating surface, communication elements of the soundproofing layer with adjacent external parallel plates (Patent of the Russian Federation on ПМ №134555, IPC: E04B 1/84, publ. November 20, 2013 Bull. No. 32).

The impossibility of achieving the result achieved by the claimed design by the indicated technical solution is caused by the fact that the external parallel plates are made of sheet building material: gypsum, gypsum plasterboard, cement-bonded, gypsum-fiber, wood-particle, silica-fiber, fiberglass, polyurethane foam, soundproofing foam, fiberglass, polyurethane foam, foam foam, mineral wool, penoizol, which does not allow the implementation of The adhesion of the material of the external plates into the soundproof layer and thereby improve the soundproofing properties, as well as the performance of orientation elements in the form of a U-shaped metal profile, which is also the supporting element, which in turn leads to more complicated installation and higher cost of the entire structure.

Of the known devices, the closest to the claimed device is a soundproof gypsum board for partitions, containing elements of its orientation located at its ends, external parallel plates made of gypsum binder, and a soundproof layer located between them, interacting with each other on a corresponding mating surface, communication elements of the soundproof layer with adjacent external parallel plates (RF Patent ПМ №47025, IPC: E04C 2/00, published on 08/10/2005, Bull. No. 22).

The impossibility of achieving the indicated technical solution the result achieved by the claimed design is that the communication elements of the soundproofing layer with the corresponding external parallel plates are made in the form of through or through holes located in the soundproofing layer, which complicates its design and manufacture and practically reduces to zero all soundproofing properties of these partitions due to the transmission of sound vibrations from one surface to another by communication elements, since gypsum knitting The present only fills the free space between the fragments, effectively bypassing the body sound insulating layer, the generated "sound bridges". In addition, when performing the entire soundproofing layer, or from fragments or debris from polystyrene foam or polyurethane foam, the soundproofing properties of the entire structure are reduced due to the use of low soundproofing properties of lightweight materials with closed pores. The manufacture of this design with a large number of holes also increases its cost and production time with a low soundproofing effect.

When developing the claimed design, the task was to improve the soundproofing (acoustic) properties of the structure while reducing its cost, and increasing manufacturing productivity by reducing manufacturing time.

In solving this problem, a technical result was achieved, which consists in creating a monolithic (modular) structure with a continuous internal soundproofing layer, eliminating the presence of “sound bridges” and the possibility of acoustic contacting of external gypsum boards with each other due to the formation of corresponding continuous boundary layers of strips from 0.01 up to 0.5 thickness of the sound insulation layer formed by hardening in the pores and channels of the sound insulation material along both surface mating surfaces Tei gypsum binder, which significantly reduces the amplitude of the sound vibrations extending over the entire volume of the body. The connection of the outer layers of the layers with the internal soundproofing layer is ensured by adhesion of the gypsum binder to the fibrous structure of the mineral plate of the internal soundproofing layer with partial penetration into its fibrous, with the presence of open pores and channels, its structure and gluing it with gypsum in the liquid phase during the casting process. In addition, there is no need to make through or through holes located in the soundproof layer, which simplifies the design, and thereby reduces the cost of its manufacture and at the same time increases the productivity of manufacturing by reducing the time of its manufacture, and also allows you to get away from the “sound bridges” ".

The essence of the claimed device soundproof gypsum modular design is that it contains elements of its orientation located on its ends, external parallel plates made of gypsum binder, and a soundproof layer located between them, interacting with each other on the corresponding mating surface, soundproofing communication elements layer with adjacent outer parallel plates.

New in the device is that the soundproof layer is made of fiber material with open pores and channels, and the communication elements are each made in the form of continuous boundary strips with a width of 0.01 to 0.5 thickness of the soundproof layer formed by hardened in the pores and channels along both mating surfaces with a gypsum binder.

In addition, the orientation elements can be made in the form of at least one ridge and one open groove.

As a material of a fibrous structure with open pores and channels of a soundproofing layer, medium to high density basalt insulation, light chipboard, felt, fiberglass mat, lightweight MDF (medium density fiberboard) can be used.

In addition, the ridge and open groove can be located on opposite ends of the outer parallel plates.

Patent studies did not reveal technical solutions characterized by the claimed combination of features, therefore, we can assume that the specified technical solution meets the condition of patentability “novelty”.

In addition, the proposed product is experimentally manufactured in pilot production and can later be used on an industrial scale, which corresponds to the patentability condition “industrial applicability”.

The soundproof gypsum modular device is shown in the drawings, which depict:

FIG. 1 is a front view of a soundproof gypsum modular structure;

FIG. 2 is a side view of FIG. one;

FIG. 3 is a top view;

FIG. 4 is a view of the assembly assembly, side view;

FIG. 5 - variability of the design with a different arrangement of grooves and ridges. Side view.

The soundproof gypsum modular design is made in the form of a tongue-and-groove plate containing external parallel plates 1 and 2 (Figs. 1, 2, 3) made of gypsum binder, and the soundproof layer 3 located between them with the formation of at least one ridge 4 and one open groove 5, which is the orientation elements of the inventive modular design, located at its ends, which allows for further installation when laying plates, apply the principle of their joining, for example, in partitions. The crest 4 and the open groove 5 are preferably located on opposite ends of the outer parallel plates 1 and 2. The ends of the outer parallel plates 1 and 2, including the crest and groove, are load-bearing elements in the structure. For joining the heat-insulating layers of adjacent tongue-and-groove plates, it is provided that orientation elements are made in the form of a ridge 4 and a groove 5 at the ends of the soundproof layer of the plates.

The soundproofing layer is made of fiber material with open pores and channels, having a bulk density of 100 kg / m ³ to 800 kg / m ³ and a thickness of 5 mm to 100 mm, that is, having a structure property in which the pores and channels communicate with the surrounding environment and among themselves. The following materials can be used as such material: medium to high density basalt insulation, light-particle board, felt, fiberglass mat, lightweight MDF (medium-density fiberboard) or any other fibrous material with sufficient tear-off strength and corresponding aggregate properties declared to customer requirements. The sound insulation layer can be made simultaneously heat-insulating.

External dimensions and product quality requirements comply with GOST 6428-83. It is possible to use water-repellent additives for the production of products intended for work in rooms with increased requirements for high humidity.

Plates 1 and 2 interact with the soundproofing layer 3 along the corresponding mating surfaces 6 and 7 through communication elements made each in the form of continuous boundary strips 8 and 9 with a width of 0.01 to 0.5 of the thickness of the soundproofing layer formed by hardened in the pores along both mating surfaces 6 and 7 with a gypsum binder. The thickness “h” of strips 8 and 9 depends on the depth of penetration of the gypsum in the manufacture of the plate and is dictated by the assortment of requirements for increasing the average weighted rate (R _w ) of sound attenuation, including those associated with temperature and humidity conditions in the rooms. In accordance with SNIP 20-03-2003 “Protection from noise”, the level of sound attenuation in residential premises should be at least 41 dB. The parameter (R _w ) takes on a value in the indicated interval h from 43 dB to 53 dB and, in addition, depends on the density of the soundproofing layer, the characteristics of the material from which it is made, its thickness and the structure of pores and channels and, in each case, depends on customer requirements.

When assembling the partition from tongue-and-groove plates of the claimed design, they can be connected by applying seams 10 (Fig. 4) of gypsum or other glue to the ends located along the line of joining of the corresponding crest and groove of plates 1 and 2. In this case, the adjacent adjacent soundproof layers 3 are joined along the line of their contact 11.

The manufacture of a tongue-and-groove plate is carried out by mixing gypsum binder with water, pouring molds followed by pushing out the hardened plates with hydraulic pushers or disassembling the molds to remove the product. The technology involves the vertical installation of soundproofing materials in the molding cassette, soundproofing material 3 is laid in the center, fixed by retaining devices (retractable clamps), for example, movable stops, rods, or surfaces that prevent it from shifting, and gypsum binder is poured in accordance with GOST 23789, GOST 125 or TU of the manufacturer of the brand not lower than G-4 on both sides of layer 3 to a level flush (flush) with its upper surface. The molding cassette is shaped around its perimeter, providing for the possibility of laying a soundproof layer in such a way as to guarantee the manufacture of a groove and a ridge. The dimensions of the soundproofing material correspond to the dimensions of the manufactured plate according to GOST 6428-83, and the thickness may vary depending on customer requirements for the thickness of the plate and acoustic properties.

In the process of hardening the gypsum binder, the material of the soundproofing layer 3 is impregnated to a depth in accordance with its properties, which ensures high adhesion of gypsum over the entire contact surface along both mating surfaces 6 and 7 with gypsum binders until the entire volume of layer 3 is gypsum when it penetrates into its pores and channels all the way to the middle.

The depth of impregnation of layer 3 with gypsum is also set by the hardening time. So, for example, the setting time of the shut gypsum binder can vary from 2 to 20 minutes when using gypsum binder GOST 23789, GOST 125 or TU of a brand manufacturer of at least G-4.

An additional positive result is the ability of gypsum to expand upon hydration up to 1% of the volume, which leads to excessive pressure on the walls of the mold and the surface of the soundproof layer 3, which in turn leads to better penetration of the gypsum binder into its open pores and channels.

As a result of this manufacturing technology, the plate module is formed as a single monolithic unit with single-phase molding.

After hardening of the gypsum binder in a snap and the product is set to the required strength, the products are ejected from the molding cassette or dismantled manually.

Correction when cutting the crest of the upper plate after installing the partition is done with a special knife, similar to cutting the crests of tongue-and-groove plates in accordance with GOST 6428-83.

The finished product has improved acoustic properties due to the fact that the sound wave, when passing through the nearest, for example, outer plate 1, excites vibrations of the primary gypsum layer, then passes through the fibrous structure of the soundproofing material of layer 3 and reduces its amplitude due to mechanical friction. Coming to the secondary surface 7 of the plate 2 in a weakened state, the wave excites oscillations of even smaller amplitude. Thus, the product operates in the lower and middle ranges of sound waves in the speech range, damping the sound. Upper registers are simply reflected due to the strength properties of gypsum surfaces, as well as their mass.

Sound-insulating tongue-and-groove gypsum boards can be used both for the construction of self-supporting walls and partitions, and to improve the sound insulation of existing walls and partitions by installing additional partitions from tongue-and-groove gypsum boards, by attaching to them including, for example, using a sticker on existing walls.

The possibility of implementing the inventive utility model is confirmed by the use of well-known elements, as well as materials with optimal performance characteristics used in the construction field, including those used at the level of functional generalization, with the achievement of a technical result consisting in increasing the acoustic properties of the structure with a value of R_w, meeting the specified requirements of the customer, while reducing its cost by simplifying the connection of external parallel slabs with a soundproofing layer and also increasing production productivity by reducing its manufacturing time, eliminating the need for a large number of communication elements in the form of various holes.

Claims (4)

1. Soundproof gypsum modular design containing elements of its orientation located at its ends, external parallel plates made of gypsum binder, and a soundproofing layer located between them, interacting with each other on a corresponding mating surface, communication elements of the soundproofing layer with adjacent outer parallel plates characterized in that the soundproof layer is made of fiber material with open pores and channels, and the communication elements are made azhdy as solid border strips of width 0.01 to 0.5 the thickness of the sound-insulating layer formed by the hardened in the pores and channels along the mating surfaces of both gypsum binder. 2. Soundproof gypsum modular construction according to claim 1, characterized in that the orientation elements are made in the form of at least one ridge and one open groove. 3. Soundproof gypsum modular construction according to claim 1, characterized in that as the material of the fibrous structure with open pores and channels of the soundproofing layer is used: basalt insulation from medium to high density, light wood-chip sheet, felt, fiberglass mat, light MDF. 4. Soundproof gypsum modular construction according to claim 1 or 2, characterized in that the ridge and open groove are located on opposite ends of the external parallel plates.

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