AU2019100306A4 - Prefabricated high-strength and high-efficiency thermal insulation composite external wall panel - Google Patents
Prefabricated high-strength and high-efficiency thermal insulation composite external wall panel Download PDFInfo
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- AU2019100306A4 AU2019100306A4 AU2019100306A AU2019100306A AU2019100306A4 AU 2019100306 A4 AU2019100306 A4 AU 2019100306A4 AU 2019100306 A AU2019100306 A AU 2019100306A AU 2019100306 A AU2019100306 A AU 2019100306A AU 2019100306 A4 AU2019100306 A4 AU 2019100306A4
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
- E04C2/2885—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material with the insulating material being completely surrounded by, or embedded in, a stone-like material, e.g. the insulating material being discontinuous
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
- E04C2/049—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres completely or partially of insulating material, e.g. cellular concrete or foamed plaster
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
- E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame
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- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
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- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Building Environments (AREA)
Abstract
Abstract of Instruction This invention publicizes a prefabricated high-strength and high-efficiency thermal insulation composite external wall panel and its preparation method. This composite external wall panel has a steel skeleton box structure, a concrete layer and an insulation layer; the concrete layer coated on the skeleton box forms a rectangular shape box and the insulation layer fills the interior of the box; the skeleton box is a frame in rectangular shape, each surface of the rectangular frame is a mesh, and the concrete layer is coated on each mesh surface. To manufacture composite external wall panel, concrete, which has higher strength and service life than the insulation material, is used to make the exterior of the box, with insulation material inside the box. When an external force acts on the composite wall panel, it will not impact on the insulation material, and hence improving the service life of this composite wall panel; since the concrete is coated on a mesh surface, the structure will reinforce the strength of the concrete layer, and therefore reinforce the strength of the whole composite external wall panel to make it safe to be used in high-rise buildings. Drawings -14 A |I A Picture 1 Picture 2
Description
Technical Field
This invention involves a wall panel, and specially involves a prefabricated highstrength and high-efficiency thermal insulation composite external wall panel and its preparation method.
Background Technology
Due to its light weight, prefabricated wall panel requires less on-site labour intensity and improves on-site construction efficiency, so it has been widely applied in the construction industry. The prefabricated wall panel is divided into interior wall panel and external wall panel according to the function. The interior wall panel is mainly used as a load-bearing component, and can be made with one single material; the external wall panel generally is non-load bearing wall panel, it also needs to have the functions of heat preservation, thermal insulation and waterproof, etc. So one single material is difficult to meet all these requirements. Therefore, composite wall panel is generally made of multiple materials.
Patent No.CNIOl 144294B mentions a prefabricated thermal insulation wall and the patent publicized a single wall panel mainly consists of steel frame, protective frame, inner layer, outer layer, foamed cement insulation core layer and steel truss; more specifically, a steel frame and a protective frame are set up at the edge of the single wall panel; a steel truss and a three-dimensional steel net are set up in the single wall panel; the inner surface of single wall panel is equipped with an inner surface layer with a material having crack resistance property; its middle part is an insulation core layer made of foamed cement; The outer surface of single wall panel is equipped with an outer surface layer made of a material having crack resistance property; the crackresistant material is a steel mesh, and the inner layer and the outer layer are made of cement. This prefabricated insulation wall panel has the properties of thermal insulation and light weight. However, since the wall panel is a layered structure overlay by an inner layer, an insulation core layer and an outer layer, and the insulation layer is made of foamed cement which has lower density than cement, so the strength of insulation layer is lower than the cement layer. Therefore, after installing this wall panel, when the outer layer of the wall panel suffers external pressure, it will transmit the pressure to the inner layer through the insulation layer, or when the wall panel suffers external shear force, since the strength of the insulation layer is lower than the strength of the cement layer, the insulation layer will be damaged first to reduce the insulation performance of this wall panel and shorten the service life of the wall panel. Meanwhile, the wall panels of high-rise buildings needs to be more wind resistant than the wall panels of low-rise buildings, therefore this low-strength wall panel with insulation function generally is only used in low-rise buildings and cannot be used in high-rise buildings.
2019100306 21 Mar 2019
Description of this Invention
According to one aspect of this invention, it aims to offer a prefabricated high-strength and high-efficiency thermal insulation composite external wall panel which has highstrength and long service life, in order to solve the problem that general assemble-type thermal insulation external wall panel has low strength and short service life and cannot be used for high-rise buildings.
This prefabricated high-strength and high-efficiency thermal insulation composite external wall panel has a box-type skeleton, a concrete layer and an insulation layer; the concrete layer is coated on the box-type skeleton, forms a box of rectangular shape; the insulation layer fills in side of the box; the box-type skeleton is a rectangular-shape frame, and each surface of the rectangular frame is a mesh structure, and the concrete layer is coated on each surface of the rectangular frame. In the embodiment of this invention, it uses concrete to make a box, and uses the insulation layer to fill the concrete box, with each surface of this composite external wall panel produced is the concrete layer. When installing this composite external wall panel on the building (for example, install one of the surface having the largest area of the rectangular composite external wall panel towards the building, and the opposite surface against the building), the surface of this composite external wall panel facing out will be subjected to external forces, such as wind, but since each surface of the composite external wall panel in this invention embodiment is coated with concrete layer, the concrete layer (i.e. the surface facing out) of this composite external wall panel will pass the external forces onto the opposite concrete layer surface (facing inside the building) through the adjacent concrete layers of this composite external wall panel. It will transmit the external forces to the whole building through the concrete layers of this external wall panel. Obviously, the concrete layer of this composite external wall panel facing in and out the building are connected through the concrete layers, and will transmit the external forces to the whole building through the connected concrete layers. Since the strength and rigidity of concrete is higher than general insulation materials, the deformation of concrete is smaller than that of thermal insulation material under the effect of external forces. Therefore, when the composite external wall panel is subject to an external force, the force transmission process will not impact on the thermal insulation material inside the concrete box; meanwhile, since the strength of concrete is higher than general insulation materials, the service life of concrete is longer than general insulation materials. Therefore, the composite external wall panel avoids reduced insulation property and shortened service life due to the destruction of the thermal insulation material caused by external forces, and hence improves the insulation property and service life of this composite external wall panel. Since the concrete is coated on the surface of box-type skeleton, each surface of the box-type skeleton uses mesh structure, the mesh structure surfaces enhance the strength of the concrete layer, reinforce the strength of the concrete box, and can further improve the strength of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel. So this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel can be used in high-rise buildings, extending the application scope of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel.
In some modes of execution, the mesh structure is formed by multiple bars, the surface with the largest area of the skeleton box have at least one bars that have external parts which
2019100306 21 Mar 2019 extends outside the frame structure; the external parts of the bars are parallel to the surface with the largest area of the rectangular frame; the concrete layer on the rectangular surface with the largest area extends along the bars’ external parts where they are located and forms the external bar surface, and the external bar surface encloses a slot bar with the surface of the box between them. Therefore, when installing this composite external wall panel on the building, it can be fastened on the building or the steel column of the building structure through the slot bar of this composite external wall panel to achieve rapid installation of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel and improve the installation efficiency; Meanwhile, when an external force acts on this composite external wall panel, the concrete layer of this composite external wall panel outside the building will not only transmit the force onto the building through the connected concrete, but also will transmit the force to the building or the steel column through the slot to disperse the external force of this composite external wall panel, reduce the impact of the external force to this composite external wall panel, and extend the service life of this composite wall panel; At the same time, since this composite external wall panel is fastened on the building or the steel column of the building structure, this composite external wall panel will not easily fall off the building, and therefore increase the stability of this composite external wall panel installed on the building.
In some modes of execution, the skeleton box has fastening holes, which is located on the pair of surfaces with the largest area, penetrating to the opposite surface. Therefore, when installing this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel on the building, it can be screwed or bolted through the preset fastening holes on the box to further fasten this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel on the building, and ensure the installation stability of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel; Meanwhile, since the fastening hole is preset on the box, when installing this composite external wall panel on the building using screws or bolts, there's no need to punch a hole on this composite external wall panel by using electric drill or other tool when installing this composite external wall panel. It will improve the installation efficiency when installing this composite external wall panel on the building by using preset fastening holes and screws or bolts.
In some modes of execution, reinforced metal pieces are set up at the location corresponding to the fastening holes on the box-type skeleton, and these metal pieces have holes corresponding to the fastening holes. Since the holes of the reinforcing pieces set on the box-type skeleton are corresponding to the fastening holes, the prefabricated high-strength and high-efficiency thermal insulation composite external wall panel can be screwed and installed on the building by passing through two corresponding holes (the fastening holes and the holes on the reinforcement pieces). When this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel suffers its own gravity or external shear force, it will apply shear force to the screws, and this composite external wall panel has a tendency to move relative to the screws. If the reinforcement pieces are not set, this movement will enlarge the diameter of the fastening holes, lead to an increase in space between the fastening hole and the screws, and loosen the position of this composite external wall panel relatively. In the most severe case, it will cause this composite external wall panel to fall off from the building. When the reinforcing pieces are set, the steel pieces are free from chipping, so even there is movement between this composite external wall panel and the screws,
2019100306 21 Mar 2019 the space between the screws and the reinforced pieces and the space between the screws and the fastening holes of the concrete layer will not increase, and therefore the screws will not fall off from this composite external wall panel. It will further ensure the installation stability of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel on the building.
In some modes of execution, the fastening holes are set up on the four corners of the pair of surfaces with largest area. This is to avoid the warp and twist of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel caused by extreme heat and cold, and to make this prefabricated highstrength and high-efficiency thermal insulation composite external wall panel tightly fit to the wall.
In some mode of execution, the inside of the box-type skeleton has multiple support bars. The support bars are connected between the pair of surfaces with the largest area. Therefore, the bars, which connects the surface pair with the largest area of the box skeleton from inside, are connected to improve the box-type skeleton’s compressive strength and hence improve the overall strength of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel and prolongs the service life of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel.
In some modes of execution, the insulation layer is made of foamed cement. Since foamed cement and concrete are homogeneous materials, when filling foamed cement into the box made of concrete, the joint surface of foamed cement and concrete can be fully integrated, and help reinforce the strength of the joint surface and prolong the service life of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel; moreover, since the insulation material is made of foamed cement, when filling foamed cement into the box made of concrete, the foamed cement is fixed together with the supporting bars in the box. This increases the strength of the insulation layer by supporting bars, and improves the overall strength of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel.
In some modes of execution, the rectangular frames on the mesh-structured surfaces with the largest area have supporting bars extending along two diagonal lines of each surface, and both bars ends at the corner of the diagonal line where they are located respectively. Therefore, this will stabilize the shape of the largest surfaces of the boxtype skeleton, avoid deformation of the box-type skeleton surfaces, ensure the stability of the concrete box after concrete is coated on the surface, and make it easy for the assembling of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel.
According to the second part of this invention, it provides a preparation method for the prefabricated high-strength and high-efficiency thermal insulation composite external wall panel. The prefabricated high-strength and high-efficiency thermal insulation composite external wall panel manufactured using this method has high-strength and long service life, and the preparation method itself is simple, fast and can be used in automated large-scale production. Meanwhile, the prefabricated high-strength and high-efficiency thermal insulation composite external wall panel has high stability and
2019100306 21 Mar 2019 easy to assemble.
The preparation method for prefabricated high-strength and high-efficiency thermal insulation composite external wall panel includes following steps:
S101: Weld multiple bars/bars (111) together to form a box frame with a rectangular shape, and weld each surface of the frame to be like a mesh;
SI02: Place the frame into the mold cavity of external mold, where the mold cavity of the external mold should be suitable for the above frame;
SI03: Pour liquid concrete into the mold cavity of external mold, to the extent that the amount of concrete poured should not be more than one-half of the volume of the cavity of the external mold;
SI04: Rotate the external mold around a pivot using a centrifugal device, coating the concrete layer evenly over two opposite surface of the frame and forming a concrete cavity with two sides penetrating through. The pivot is an axis connecting the centers of any pairs of opposing surface of the frame;
SI05: Inject concrete and thermal insulation material into the concrete cavity with two side run-through. The injected concrete coated on the two surface of the frame connected by the pivot, and forms the box filled with thermal insulation material;
SI06: When the coated concrete and the filled insulation material are solidified, remove the box from the external mold, and this becomes the prefabricated high-strength and high-efficiency thermal insulation composite external wall panel.
This composite external wall panel made using an external mold, is not only consistent in size which implies product standardization, but also has consistent and evenly coated concrete using a centrifugal device. The production can be fully automated, and when the concrete is coated using the centrifugal action by the centrifugal device, the density of the concrete layer coated on the surface of the frame is much higher compared to traditional method. Therefore, the strength of the concrete box is further improved.
According to the other part of this invention, it provides the preparation method for prefabricated high-strength and high-efficiency thermal insulation composite external wall panel that can be easily and quickly installed and resistant to external forces. The prefabricated high-strength and high-efficiency thermal insulation composite external wall panel produced using this method has high-strength, long service life, and standardized sizes, and the preparation method is simple, fast and can be used in automated large-scale production. Moreover, the prefabricated high-strength and highefficiency thermal insulation composite external wall panel can be quickly installed and resistant to external forces.
The preparation method for prefabricated high-strength and high-efficiency thermal insulation composite external wall panel that can be quickly installed and resistant to external forces includes the following steps:
S201: Weld multiple bars together to form a box frame with a rectangular shape, and weld each surface of the frame to be like a mesh. The surface with the largest area of the skeleton box have at least one bar that have external parts which extends outside the frame structure. The external bars enclose through slots with the surface of the box between them.
S202: Place suitable strip mold in the through slot;
S203: Place the frame with extended bars (112) into the mold cavity of the external
2019100306 21 Mar 2019 mold, where the mold cavity of the external mold matches the frame with extended bars (112);
S204: Pour liquid concrete into the mold cavity of external mold, to the extent that the amount of concrete poured should not be more than one-half of the volume of the mold cavity of the external mold;
S205: Rotate the external mold around a pivot using a centrifugal device, coating the concrete layer evenly over two opposite surface of the frame and forming a concrete cavity with two sides penetrating through. The pivot is an axis connecting the centers of any pairs of opposing surface of the frame;
S206: Inject concrete and thermal insulation material into the concrete cavity with two side run-through. The injected concrete coated on the two surface of the frame connected by the pivot, and forms the box filled with thermal insulation material;
S207: When the coated concrete and the filled insulation material are solidified, remove the box from the external mold, take the strip mold from the through slot, and this becomes the prefabricated high-strength and high-efficiency thermal insulation composite external wall panel.
Illustration for the drawings
Picture 1 is the structural sketch of the prefabricated high-strength and high-efficiency thermal insulation composite external wall panel;
Picture 2 is the A-A cross-sectional structural sketch of the prefabricated high-strength and high-efficiency thermal insulation composite external wall panel shown in picture i;
Picture 3 is the structural sketch for the box-type skeleton of the prefabricated highstrength and high-efficiency thermal insulation composite external wall panel shown in picture 2;
Picture 4 is the B-B cross-sectional structural sketch of the prefabricated high-strength and high-efficiency thermal insulation composite external wall panel shown in picture 2;
Picture 5 is the structural sketch of the prefabricated high-strength and high-efficiency thermal insulation composite external wall panel when it is assembled;
Picture 6 is the C-C cross sectional sketch of the prefabricated high-strength and highefficiency thermal insulation composite external wall panel when it is assembled shown in picture 5;
Picture 7 is the first preparation method for the prefabricated high-strength and highefficiency thermal insulation composite external wall panel;
Picture 8 is the second preparation method for the prefabricated high-strength and highefficiency thermal insulation composite external wall panel with slots.
2019100306 21 Mar 2019
Specific implementation methods
We will explicitly discuss this invention in detail.
Picture 1 to picture 4 presents one of the implementation methods of prefabricated highstrength and high-efficiency thermal insulation composite external wall panel.
As shown in Picture 2, this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10) has a box-type skeleton (11), a concrete layer (12) and a thermal insulation layer (13); the concrete layer (12) is coated on the box-type skeleton (11), forms a box of rectangular shape, the insulation layer fills the inside of box; The box-type skeleton (11) is a rectangular-shape frame, and each surface of the rectangular frame is a mesh structure; the concrete layer is coated on each surface of the rectangular frame, implying that each mesh-structural surface of the box is coated with concrete.
In this embodiment, as shown in picture 2, since the box-type skeleton (11) is a rectangular-shape frame, and this frame is the final structure that supports this composite external wall panel. Opposite surfaces of the box have the same area, and when installed on the building the pair with the largest area has one surface facing the inside of the building (114) and the opposite surface facing the outside of the building (113). The surface between surface facing in (114) and the surface facing out (113) is the side surface (115).
Each surface of the rectangular frame is a mesh structure constituted by multiple reinforced bars (111). The bars (111) on the same surface can be randomly distributed. However, in order to increase the strength of the coated concrete on the mesh structure, the bars (111) on the same surface can be distributed as shown in picture 2 to picture 4. Furthermore, to improve the overall strength of this frame and the strength of the concrete box, the bars (111) on the side surfaces of the frame (surfaces that do not have the largest area) are perpendicular to the bars (111) on the pair of surfaces having the largest area.
Furthermore, to increase the strength of the box-type skeleton (11), the concrete coated box and the strength of the insulation layer (13) inside in the box, the inside of the box (11) can have multiple support bars (1111). The support bars connect the pair of surfaces with the largest area on the rectangular frame, perpendicular to the bars (111) on the surfaces with the largest area, and hence further reinforce the overall strength of this frame.
Since the prefabricated high-strength and heat-insulation composite external wall panel (10) is made by filling the insulation material into the box made of concrete, when installing this composite external wall panel on the building, one of the largest surface of this composite external wall panel is installed facing inside the building, and the opposite surface is installed facing outside the building. (The largest surfaces of this composite external wall panel are corresponding to the largest surfaces of the box frame) . Since the strength and rigidity of concrete is higher than general insulation material, when an external force acts on the composite wall panel, the deformation of the concrete layer (12) under external forces is less than that of the insulation layer (13). After the composite external wall panel is installed on a building, when it is subject to external forces such as wind, the impact on the concrete layer facing outside the
2019100306 21 Mar 2019 building (113) will be transmitted through the concrete layer (12) on the side adjacent to it (that is the layer (115) of this composite external wall panel) to the concrete layer facing inside the building (114), and then will be transmitted onto the building. Meanwhile, since the strength of concrete is higher than general insulation material, the service life of concrete is longer than general insulation material. When an external force acts on this composite external wall panel, it is impacting the concrete layer (12) of this composite external wall panel. That means that the service life of this composite external wall panel is determined by the service life of the concrete layer, and therefore implies higher service life of the external wall panel. Moreover, since the concrete is coated on the surface of the rectangular frame and each rectangle surface of the frame is a mesh structure formed by the bars (111). The bars (111) on the surface of the frame increase the strength of the concrete layer (12), improve the strength of the concrete box, and therefore improve the strength of this prefabricated high-strength and highefficiency thermal insulation composite external wall panel (10). In conclusion, this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10) is strong enough to be used in high-rise buildings, which broadens the scope of applications of the prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10).
To increase the strength of the box-type frame (11), further improve the strength of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10) and extend the service life of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10). The bars (111) constituting the box-type frame (11) is made of steel. It will ensure the strength of the box-type skeleton (11). The material is abundant and low-cost.
In this embodiment, in order to ensure better thermal insulation of this prefabricated highstrength and high-efficiency thermal insulation composite external wall panel (10), reduce the weight of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel, and reduce on-site labour intensity for the installation of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10), and further improve the strength of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10), the insulation layer (13) filled inside the concrete box is made of foamed cement. Since the foamed cement and concrete are homogeneous materials, when filling foamed cement into the concrete box, the joint surface between foamed cement and concrete can be fully integrated. It will enhance the joint strength between the foamed cement and concrete box, and prolong the service life of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10).
As shown in picture 4, to stabilize the shape of this box-type frame (11), and avoid the deformation of the box structure and the coated concrete and ultimately the composite external wall panel, the surfaces on the box-type frame (11) with the largest area have supporting diagonal bars (119) extending along two diagonal lines of the surface respectively, and both ends of the bars (119) are respectively set on the comers of the diagonal lines.
As shown in picture 2, to facilitate the installation of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10) on the building or on the structure steel column (16), and achieve the fast installation and improve efficiency, the surface with the largest area of the skeleton box have at least one bar (111) that have external parts
2019100306 21 Mar 2019 which extends outside the frame structure (112). The external parts of the bars (112) is parallel to the surface with the largest area of the rectangular frame. The concrete layer (12 ) on the rectangular surface with the largest area extends along the bars ’ external parts (112) where they are located and forms the external bar surface (116). The external bar surface (116) encloses a slot bar (117) with the surface of the box between them. The slot bar (117) is designed to fit into the building or the steel structure column (16). The slot bar will be fastened on the building or the steel column (16). As shown in picture 5 and picture 6, multiple prefabricated high-strength and high-efficiency thermal insulation composite external wall panels (10) are assembled onto the steel column (16). The bars (111) on the largest surface and the extended bars (112) can be connected by welding or gluing, or may be one-piece. The direction of this prefabricated high-strength and highefficiency thermal insulation composite external wall panel (10) is not limited to one side since it has slot bars (117) on all four sides, it can be put together to cover the whole wall. After installing this composite external wall panel with slot bars (117) on the building or the steel column (16), when an external force acts on the surface of this composite external wall panel, the concrete layer facing out (113) can transmit force through the adjacent concrete layer (12) and also the slot bars (117) onto the building or the steel columns (16), disperse and reduce any impact and extend the service life of this composite wall panel. Meanwhile, since this composite external wall panel is fastened on the building or the steel column (16), this composite external wall panel is secured and stabilized on the building.
To further secure this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10) on the building, as shown in picture 1, picture 2, picture 4 to picture 6, the box frame also has fastening holes (14), which arc located on the surfaces with the largest arcaand penetrate to the opposite surface. The fastening holes (14) can be a through-hole or a screw-hole. When installing this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10) on the building, screws (15) or bolts can be used to pass through the fastening holes (14) on the frame to further fasten this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10) on the building, and ensure the installation stability of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10); and since the fastening holes (14) are pre-set on the frame, when installing there's no need to punch holes by using electric drill or other tools. It will improve the installation efficiency when securing this composite external wall panel on the building using screws or bolts.
Furthermore, there is a support structure to support the wall panel’s own weight or external forces so that the forces will not directly impact on the concrete layer (12) or the thermal insulation layer (13). As shown in picture 4, reinforced bars (118) are set at the locations corresponding to the fastening holes (14) on the box-type skeleton (11), with through-holes corresponding to the fastening holes (14). After securing this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10) on the building using screws (15) through the fastening holes (14), the panel’s weight or any external forces will be transmitted to the screws (15), making this composite external wall panel moving relatively to the screws (15). If the reinforced bars (118) are not set up, the particles of the concrete layer (12) are likely to fall off in the long-term effect of this relative movement. It will increase the sizes of the fastening holes (14), and then lead to an increase in space between the fastening holes (14) and the screws (15), and cause this composite external wall panel to become loose on the building. In severe cases, it might also cause this composite external wall panel to fall off the building. After setting the steel reinforced bars (118), since the steel bars (118) are
2019100306 21 Mar 2019 durable and free from chipping under movements, the space between the screws (15) and the through-holes of the reinforced bars (118) and the space between the screws (15) and the fastening holes (14) of the concrete layer will not change. It will further ensure the installation stability of this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10) on the building.
To tightly install this prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10) on the building and avoid the warp and twist caused by heat or cold, there are the fastening holes (14) on the four comers of the box surfaces with the largest area. Preferably, the fastening holes (14) are symmetrically arranged.
Picture 7 presents the preparation method for prefabricated high-strength and highefficiency thermal insulation composite external wall panel (10) according to one implementation method of this invention.
The preparation method for prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10) includes following steps:
S101: Weld multiple bars/bars (111) together to form a box frame with a rectangular shape, and weld each surface of the frame to be like a mesh.
SI02: Place the frame into the mold cavity of external mold, where the mold cavity of the external mold should be suitable for the above frame.
SI03: Pour liquid concrete into the mold cavity of external mold, to the extent that the amount of concrete poured should not be more than one-half of the volume of the cavity of the external mold.
SI04: Rotate the external mold around a pivot using a centrifugal device, coating the concrete layer evenly over two opposite surface of the frame and forming a concrete cavity with two sides penetrating through. The pivot is an axis connecting the centers of any pairs of opposing surface of the frame; preferably the box frame is set into the mold with equivalent distance between each surface of the frame and the mold cavity. The external mold can be in any shape and only needs to match with its mold cavity with the shape of frame. The mold cavity can have only one opening, and the size of the opening much be large enough to place the frame into the cavity. To avoid any leakage during the centrifugal rotation, it needs a removable cap to cover the opening with its handle outside. The mold is generally made of steel.
SI05: Inject concrete and thermal insulation material into the concrete cavity with two side run-through. The injected concrete coated on the two surface of the frame connected by the pivot, and forms the box filled with thermal insulation material.
SI06: When the coated concrete and the filled insulation material are solidified, remove the concrete box from the outer mold, and this forms the prefabricated high-strength and high-efficiency thermal insulation composite external wall panel. To facilitate the removal of the concrete box and to make it easier to place the box frame inside the mold, the external mold can be designed to be able to be disassembled into a number of pieces. Therefore, when it is necessary to place the frame into the cavity of the mold
2019100306 21 Mar 2019 or take the box out, the mold can be broken down by removing the connection structure between the modules.
This composite external wall panel made using an external mold, is not only consistent in size which implies product standardization, but also has consistent and evenly coated concrete using a centrifugal device. The production can be fully automated, and when the concrete is coated using the centrifugal action by the centrifugal device, the density of the concrete layer (12) coated on the surface of the frame is much higher compared to traditional method. Therefore, the strength of the concrete box is further improved.
Picture 8 presents the preparation method for prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10) according to the other implementation method of this invention to obtain high installation efficiency and high strength prefabricated highstrength and high-efficiency insulation composite external wall panel (10).
The preparation method for prefabricated high-strength and high-efficiency thermal insulation composite external wall panel includes following steps:
S201: Weld multiple bars (111) together to form a box frame with a rectangular shape, and weld each surface of the frame to be like a mesh. The surface with the largest area of the skeleton box have at least one bar (111) that have external parts (112) which extends outside the frame structure. The external bars (112) enclose through slots with the surface of the box between them.
S202: Place suitable strip mold in the through slot; The preferred shape of the strip mold should be a solid long strip shape suitable for the through slot, and also can be a hollow strip shape suitable for the through slot. The length of the strip mold is the same as the length of the through slot. The strip mold can be made of steel or plastic.
S203: Place the frame with extended bars (112) into the mold cavity of the external mold, where the mold cavity of the external mold matches the frame with extended bars (112); The outer mold used here has the same form as the outer mold without the slot (117), with the only difference being the size the mold cavity. The form of the external mold will not be further described here.
S204: Pour liquid concrete into the mold cavity of external mold, to the extent that the amount of concrete poured should not be more than one-half of the volume of the mold cavity of the external mold.
S205: Rotate the external mold around a pivot using a centrifugal device, coating the concrete layer evenly over two opposite surface of the frame and forming a concrete cavity with two sides penetrating through. The pivot is an axis connecting the centers of any pairs of opposing surface of the frame.
S206: Inject concrete and thermal insulation material into the concrete cavity with two side run-through. The injected concrete coated on the two surface of the frame connected by the pivot, and forms the box filled with thermal insulation material.
S207: When the coated concrete and the filled insulation material are solidified, remove
2019100306 21 Mar 2019 the box from the external mold, take the strip mold from the through slot, and this becomes the prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10) with slots (117).
This composite external wall panel made using an external mold, is not only consistent in size which implies product standardization, but also has consistent and evenly coated concrete using a centrifugal device. The production can be fully automated, and when the concrete is coated using the centrifugal action by the centrifugal device, the density of the concrete layer coated on the surface of the frame is much higher compared to traditional method. Therefore, the strength of the concrete box is further improved. Moreover, by adding the strip mold, this composite outer wall panel is formed together with the slots (117), making the production simple and fast.
For making the prefabricated high-strength and high-efficiency thermal insulation composite external wall panel (10) with fastening holes (14), the screws (15) or bolts can be installed onto the fastening holes (14) before pouring the concrete. When the concrete is not completely solidified, remove the screws (15) or bolts, and wait for the concrete to solidify. Fastening holes (14) on this prefabricated high-strength and highefficiency thermal insulation composite external wall panel (10) can also be manufactured using machines after this high-strength and high-efficiency thermal insulation composite exterior wall panel (10) is formed.
The centrifugal device used in this invention refer to the centrifugal device in the present technology, as long as the device can rotate the outer mold. There is no limit to any specific forms of the centrifugal device in this invent.
The above mentioned only provides some implementations of the present invention. A person skilled in the art, without deviating from the ambit of the present invention, can still make certain modifications and improvements which are also with the scope of the protection of the present invention.
2019100306 21 Mar 2019
Editorial Note
There are two pages of claims only
2019100306 21 Mar 2019
Claims (10)
1. The prefabricated high-strength and high-efficiency thermal insulation composite external wall panel, characterized by, a skeleton box (11), a concrete layer (12) and an insulation layer (13);
The concrete layer (12) is coated on the skeleton box (11), forming a box of rectangular shape, and the insulation layer (13) fills the interior of the box;
The skeleton box (11) is a rectangular-shape frame, and each surface of the rectangular frame is a mesh. The concrete layer (12) is coated on each surface of the rectangular frame.
2. The prefabricated high-strength and high-efficiency thermal insulation composite external wall panel according to claim 1, wherein the mesh surface structure is formed by multiple bars (111). The surface with the largest area of the skeleton box have at least one bar (111) that have external parts which extends outside the frame structure (112). The external parts of the bars (112) is parallel to the surface with the largest area of the rectangular frame; The concrete layer (12) on the rectangular surface with the largest area extends along the bars’ external parts (112) where they are located and forms the external bar surface (116). The external bar surface (116) encloses a slot bar (117) with the surface of the box between them.
3. The prefabricated high-strength and high-efficiency thermal insulation composite external wall panel according to claim 2, wherein the rectangular box has fastening holes (14) located on the two surface with the largest area, penetrating and connecting the surface.
4. The prefabricated high-strength and high-efficiency thermal insulation composite external wall panel according to claim 3, wherein the reinforced metal parts (118) are set up at the location corresponding to the fastening holes (14) on the box frame (11), and there are holes on the reinforced metal parts (118) at the location corresponding to fastening hole (14).
5. The prefabricated high-strength and high-efficiency thermal insulation composite external wall panel according to claim 4, wherein the fastening holes (14) are located near the four corners of the surface of the box with the largest area.
6. The prefabricated high-strength and high-efficiency thermal insulation composite external wall panel according to claim 1 to claim 5, wherein the inside of the skeleton box (11) have multiple support bars (1111), connecting the pair of surface of the rectangular frame with the largest area.
7. The prefabricated high-strength and high-efficiency thermal insulation composite external wall panel according to claim 6, wherein the insulation layer (13) is made of foamed cement.
8. The prefabricated high-strength and high-efficiency thermal insulation composite external wall panel according to claim 6, wherein each of the largest surface of the rectangular skeleton box have two diagonal supporting bars (119) connecting along two diagonal lines of the surface respectively, and both ends of the supporting bars (119) extends to the comers on their diagonal line respectively.
2019100306 21 Mar 2019
9. The preparation method for the prefabricated high-strength and high-efficiency thermal insulation composite external wall panel includes the following steps:
S101: Weld multiple bars (111) together to form a box frame with a rectangular shape, and weld each surface of the frame to be like a mesh;
SI02: Place the frame into the mold cavity of external mold, where the mold cavity of the external mold should be suitable for the above frame;
SI03: Pour liquid concrete into the mold cavity of external mold, to the extent that the amount of concrete poured should not be more than one-half of the volume of the cavity of the external mold;
SI04: Rotate the external mold around a pivot using a centrifugal device, coating the concrete layer evenly over two opposite surface of the frame and forming a concrete cavity with two sides penetrating through. The pivot is an axis connecting the centers of any pairs of opposing surface of the frame;
SI05: Inject concrete and thermal insulation material into the concrete cavity with two side run-through. The injected concrete coated on the two surface of the frame connected by the pivot, and forms the box filled with thermal insulation material;
SI06: When the coated concrete and the filled insulation material are solidified, remove the box from the external mold, and this becomes the prefabricated high-strength and high-efficiency thermal insulation composite external wall panel.
10. The preparation method for the prefabricated high-strength and high-efficiency thermal insulation composite external wall panel includes the following steps:
S201: Weld multiple bars (111) together to form a box frame with a rectangular shape, and weld each surface of the frame to be like a mesh. The surface with the largest area of the skeleton box have at least one bar (111) that have external parts which extends outside the frame structure (112). The external bars (112) enclose through slots (11) with the surface of the box between them.
S202: Place suitable strip mold in the through slot;
S203: Place the frame with extended bars (112) into the mold cavity of the external mold, where the mold cavity of the external mold matches the frame with extended bars (112);
S204: Pour liquid concrete into the mold cavity of external mold, to the extent that the amount of concrete poured should not be more than one-half of the volume of the mold cavity of the external mold;
S205: Rotate the external mold around a pivot using a centrifugal device, coating the concrete layer evenly over two opposite surface of the frame and forming a concrete cavity with two sides penetrating through. The pivot is an axis connecting the centers of any pairs of opposing surface of the frame;
S206: Inject concrete and thermal insulation material into the concrete cavity with two side run-through. The injected concrete coated on the two surface of the frame connected by the pivot, and forms the box filled with thermal insulation material;
S207: When the coated concrete and the filled insulation material are solidified, remove the box from the external mold, take the strip mold from the through slot, and this becomes the prefabricated high-strength and high-efficiency thermal insulation composite external wall panel.
2019100306 21 Mar 2019
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| CN201810258240.X | 2018-03-27 | ||
| CN201810258240.XA CN108412117B (en) | 2018-03-27 | 2018-03-27 | Preparation method of assembled high-strength high-efficiency heat-insulation composite external wall panel |
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| CN112982719A (en) * | 2021-02-03 | 2021-06-18 | 辰泰(广德)智能装配建筑股份有限公司 | Take fast-assembling and load structure's wallboard |
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| JPH07113206B2 (en) * | 1993-02-26 | 1995-12-06 | 三基興業株式会社 | Manufacturing method of cylindrical concrete floating body |
| KR101546067B1 (en) * | 2013-10-15 | 2015-08-21 | 백규호 | Hollow concrete-filled girder and its production method |
| CN204001236U (en) * | 2014-07-31 | 2014-12-10 | 崔荣平 | Assembled wallboard Self-thermal-insulation System wall structure |
| KR20170100776A (en) * | 2016-02-26 | 2017-09-05 | 조선대학교산학협력단 | Method for manufaturing pre-cast concrete panel |
| CN107288256B (en) * | 2017-07-04 | 2023-08-22 | 山东大学 | Light composite heat-insulating external wall panel, special die and manufacturing method thereof |
| CN208056449U (en) * | 2018-03-27 | 2018-11-06 | 辰泰（广德）智能科技建筑有限公司 | The high-efficiency insulated compound external wall panel of assembled high intensity |
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