Flexible lightweight multi-layer panel for sound insulation application in construction
The present invention provides a flexible lightweight sound insulation panel composed of multiple layers aligned in a sequence of high-density sound insulation layer, sound damping layer, medium-density sound reflection layer, low-density sound absorption layer, medium-density sound reflection layer, sound damping layer, and high-density sound insulation layer. The sound damping layer is composed of polyurethane foam. The flexible lightweight multi-layer panel has Sound Transmission Class (STC) of at least 40 dB according to ASTM E90.
1 . A flexible lightweight multi-layer panel for sound insulation applications in construction, comprising:
at least two high-density sound insulation layers having a density of 2.0 g/cm 3 to 2.3 g/cm 3 ;
at least two sound damping layers;
at least two medium-density sound reflection layers having a density of 1.6 g/cm 3 to 1.9 g/cm 3 ; and
at least one low-density sound absorption layer having a density of 0.3 g/cm 3 to 0.6 g/cm 3 ;
wherein the flexible lightweight multi-layer panel has Sound Transmission Class (STC) of at least 40 dB according to ASTM E90;
wherein the at least two high-density sound insulation layers, the at least two sound damping layers and the at least two medium-density sound reflection layers are symmetrically arranged about the low-density sound absorption layer, such that the low-density sound absorption layer is positioned at a center of the panel, and is sandwiched between the medium-density sound reflection layers, the sound damping layers, and the high-density sound insulation layers.
2 . The flexible lightweight multi-layer panel of claim 1 , wherein the layers are aligned in sequence of high-density sound insulation layer, sound damping layer, medium-density sound reflection layer, low-density sound absorption layer, medium-density sound reflection layer, sound damping layer, and high-density sound insulation layer.
3 . The flexible lightweight multi-layer panel of claim 1 , wherein the layers are aligned in sequence of high-density sound insulation layer, medium-density sound reflection layer, sound damping layer, low-density sound absorption layer, sound damping layer, medium-density sound reflection layer, and high-density sound insulation layer.
4 . The flexible lightweight multi-layer panel of claim 1 , wherein the high-density sound insulation layer comprises a polymer composite comprising poly (vinyl chloride), chlorinated polyethylene, or a combination thereof.
5 . The flexible lightweight multi-layer panel of claim 1 , wherein the high-density sound insulation layer has a Shore hardness of 40A to 60A, and a thickness of 5 mm to 6 mm.
6 . The flexible lightweight multi-layer panel of claim 1 , wherein the sound damping layer comprises a polyurethane foam.
7 . The flexible lightweight multi-layer panel of claim 6 , wherein the polyurethane foam comprises:
a first reaction composition containing at least one aromatic isocyanate component with an isocyanate functionality ranging from about 2 to about 2.5; and
a second reaction composition comprising:
a diol with a hydroxyl value from 380 to 480 mgKOH/g;
a polyether polyol with a hydroxyl value from 140 to 330 mgKOH/g;
a polymer polyol with a hydroxyl value from 20 to 30 mgKOH/g;
a catalyst;
a foam stabilizer; and
water.
8 . The flexible lightweight multi-layer panel of claim 7 , wherein the first reaction composition and the second reaction composition are contacted in stoichiometric ratio of NCO:OH functionality from 0.9:1 to 1.4:1.
9 . The flexible lightweight multi-layer panel of claim 8 , wherein the first reaction composition and the second reaction composition are contacted in stoichiometric ratio of NCO:OH functionality from 1.1:1 to 1.3:1.
10 . The flexible lightweight multi-layer panel of claim 7 , the at least one aromatic isocyanate component comprises aromatic diols and polyisocyanates.
11 . The flexible lightweight multi-layer panel of claim 7 , the diol is used for enhancing mechanical strength of the polyurethane foam and constitutes a weight percentage in a total weight of a plurality of polyols ranging from 2% to 8%.
12 . The flexible lightweight multi-layer panel of claim 7 , the polyether polyol is used for enhancing mechanical strength and tuning the glass transition temperature of the polyurethane foam and constitutes a weight percentage in a total weight of a plurality of polyols from 25% to 40%.
13 . The flexible lightweight multi-layer panel of claim 7 , the polymer polyol is used for tuning softness and glass transition temperature of the polyurethane foam and constitutes a weight percentage in a total weight of a plurality of polyols from 45% to 70%.
14 . The flexible lightweight multi-layer panel of claim 1 , wherein the sound damping layer has a density of 0.2-0.3 g/cm 3 and a thickness of 2 mm to 4 mm.
15 . The flexible lightweight multi-layer panel of claim 1 , wherein the medium-density sound insulation layer comprises a polymer composite comprising poly (vinyl chloride), chlorinated polyethylene, or a combination thereof.
16 . The flexible lightweight multi-layer panel of claim 1 , wherein the medium-density sound insulation layer has Shore hardness of 60A to 80A, and a thickness of 2 mm to 4 mm.
17 . The flexible lightweight multi-layer panel of claim 1 , wherein the low-density sound absorption layer comprises a synthetic fiber comprising glass fiber, polyester fiber, or a combination thereof.
18 . The flexible lightweight multi-layer panel of claim 1 , wherein the low-density sound absorption layer has a thickness of 15 mm to 35 mm.
19 . The flexible lightweight multi-layer panel of claim 1 , wherein the flexible lightweight multi-layer panel has a total thickness in a range of 40 to 50 mm, a weight in a range of 40 kg/m 2 to 50 kg/m 2 .