CN101743365B - 复合水泥面板 - Google Patents

复合水泥面板 Download PDF

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CN101743365B
CN101743365B CN200880024349.1A CN200880024349A CN101743365B CN 101743365 B CN101743365 B CN 101743365B CN 200880024349 A CN200880024349 A CN 200880024349A CN 101743365 B CN101743365 B CN 101743365B
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林儿庆
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    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/30—Producing shaped prefabricated articles from the material by applying the material on to a core or other moulding surface to form a layer thereon
    • 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
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    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
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    • E04D11/005—Supports for elevated load-supporting roof coverings
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Abstract

本发明涉及一种用于屋顶表面的复合面板，包括：具有顶表面和底表面的芯材板，其中多个开口从所述顶表面向所述底表面延伸穿过所述芯材板；固体材料的刚性外壳，所述刚性外壳包封所述芯材板；所述固体材料的多个支持件，其中每个所述多个支持件均延伸穿过所述芯材板中的所述多个开口的一个开口；和覆盖所述芯材板的底表面的所述刚性外壳部分上的多个腿。

Description

复合水泥面板
技术领域
本发明涉及用于屋顶板或类似结构中的复合水泥面板，以及所述水泥面板的建造方法。
背景技术
图1示出混凝土屋顶板102的包层结构系统的典型结构100。在屋顶板102之上形成水泥沙基104，其中所述沙基104是砂浆层以形成斜坡或斜坡到落差梯度，以建立到排水管106和下水管108中的排水落差。防水膜110被放在水泥沙基104之上，仅被下水管108中断，并在墙壁114的内侧表面以上延伸300mm的高度112。在板102与一些墙壁114相交的地方，防水膜从水平表面到垂直表面的过渡可通过使用防水填料(如聚泡沫116)来实现。热绝缘层118构建于膜110的顶部，所述层118包括50mm厚的挤塑聚苯乙烯绝缘板。分离薄层120叠压在热绝缘层118上。最后提供75mm厚的叠合保护刮板层122，包括通过用含沥青化合物填充的接头隔开的4.5m×4.5m面板。抹灰124应用于墙壁114。
热绝缘材料118减少了通过屋顶板102到下方的建筑中的热传递。保护水泥刮板122保护热绝缘材料118和防水膜110，并承受屋顶板上的人交通。这种结构100是在现场原位构建的，以规律间隔提供膨胀接头。
结构100遭受许多问题。混凝土刮板层122中的膨胀接头是结构中的弱点和泄漏源。雨后，残留的水留在热绝缘材料118和防水膜110之间。当暴露于来自太阳的热时，水膨胀并蒸发，在热绝缘材料118上施加压力，而热绝缘材料118又将压力施加到保护刮板混凝土122上。保护刮板混凝土122和热绝缘材料118两者通常因这种应力而碎裂，导致结构100中出现泄漏和/或“疾病”。
另一个问题在于，原位包层结构使得质量控制变得困难，可对防水系统造成损坏，并在建造期间经历各种恶劣的气候而导致时间延迟。此外，在原位混合、处理和/或应用混凝土浆体可导致混乱和费力。
更进一步，在需要对下方的屋顶板进行维护的情况下，需要破坏性地移除(如通过切除)防水膜110和/或组合防水系统104、118、120、122的部件、保护刮板122以及下方的部分或全部层，由此实际上破坏了结构100。然后必须重复建造防水系统的整个过程，以重新建立防水包层。
本说明书中已包含的文件、法规、材料、设备、物件等的任何讨论仅是为了提供用于本发明的背景。不应因为其存在于本申请的每项权利要求的优先权日期之前而被认为承认任意或全部这些内容形成现有技术基础的一部分或是与本发明相关的领域的公知常识。
在整个说明书中，术语“包括/包含”应被理解为意味着包含所陈述的要素、整体或步骤、或多个要素、多个整体或多个步骤的组，但并不排除任何其他要素、整体或步骤、或多个要素、多个整体或多个步骤的组。
附图说明
图1示出典型的屋顶包层结构；
图2是根据本发明一个实施方案的复合水泥面板的水泥铸造用模板的透视图；
图3是置于图2模板中的用于建造根据本发明一个实施方案的复合水泥面板的泡沫板的透视图。
图4是显示使用图2的模板制造水泥面板的方法的流程图。
图5A是根据本发明一个实施方案的复合水泥面板的顶视图。
图5B是图5A的底视图。
图6A是图5A的前视图。
图6B是图5A的剖面侧视图。
图6C是图6B的部分放大视图。
图7A是图5A的透视底视图。
图7B是图5A的部分剖面透视图。
具体实施方式
图2显示例如由金属制成的模板2，用于铸造图7A中所示的复合水泥面板800。模板2具有形成于基表面4上的凹陷3阵列。凹陷3定位成在模板2的整个基表面4上彼此隔开。在金属模板2的两个相邻内表面214、215上提供引导台6。模板2还包括位于底表面4上的销8。销8从模板2的基表面4向上延伸。模板2的端部是沿外周边缘的上翻裙料7，以允许在水泥面板800的铸造或运输过程中容易地操作模板2。
图3示出在水泥浇铸复合水泥面板800之前置于模板2中的轻重芯材板，如泡沫板200。泡沫板200具有通过例如钻孔、冲压、切削、冲孔或在形成泡沫板的模制工艺过程中整体预制而形成于其上的通孔202。通孔202设置为，使得当泡沫板200置于模板2中时，每个通孔都面向模板2的一个凹陷。当置于模板2中时，泡沫板200安放在销8上，在泡沫板2和模板2的底表面4之间留下间隙。
图4是利用图2中所示的模板2建造水泥面板的方法300的流程图。在步骤302中，将具有形成于其上的通孔2的泡沫板200置于模板2中，其中泡沫板的两个相邻侧背靠各自的引导台6。以此方式，在泡沫板周边与模板2的内表面214和215之间留有侧间隙。
在步骤312中，制备了预混合的自流平高强度水泥浆体，其含有或不含混凝土硬化剂或化学添加剂。在步骤306中，将水泥浆体倒入泡沫板200上，并进入模板2中。在该步骤过程中，水泥浆体将填充模板2中的圆形凹陷3、泡沫板和模板2的底表面4之间的间隙、泡沫板200的周边与模板2的内表面214、215、216和217之间的间隙以及泡沫板200的孔202。在步骤308中，水泥浆体完全充满模板，并被抹平和平整。在步骤310中，使水泥浆体干燥并硬化，由此形成包封泡沫板200的水泥壳体502，并形成复合水泥面板。在步骤314中，将形成的水泥面板从模板2取下。
根据建筑屋顶条件和饰面要求，可以建造其顶面上具有合适饰面层的复合水泥面板。例如，在可选的预干燥饰面步骤318中，可将卵石倾倒在湿复合水泥面板的顶面上。然后使所述卵石附着到所述面板的顶表面上，并与面板一起干燥。或者，可将彩色水泥粉末供给到湿水泥面板的顶面上并一起干燥，从而形成有色饰面层。通过在复合水泥面板的顶面上模制或压制图案，还可形成带预定图案的印痕。在另一可选的干燥后步骤320中，作为步骤318的替代步骤，可以用瓷砖、木材面板或天然/人造石材和/或热绝缘层或防水涂料覆盖已干燥的复合水泥面板。
图5A、5B、6A、6B、6C、7A和7B示出在方法300的步骤314(示于图4中)之后生产的复合水泥面板800。参考图6A和图6B，可见泡沫板200包封在水泥壳体502中。从图6C还可见，水泥壳体的顶部204和底部206被围绕泡沫板200的水泥520a部分以及填充泡沫板200的孔202的部分约束。水泥壳体502的一些部分填充在泡沫板200的孔202中，形成柱570。这些柱570增加了水泥面板800的强度和硬度，并起分配所施加的重量(如行人交通)的作用，以减少泡沫板200被压碎的可能性。填充在模板2的圆形凹陷3中的水泥壳体的部分在复合水泥面板800的底侧250形成腿220。此外，泡沫板200通过水泥浆体中的添加剂化学粘合到水泥壳体502。
参考图7A和7B，腿220从水泥面板800的底表面250向下延伸。当平放在建筑的屋顶表面顶上时，腿220置于屋顶表面上，从而在腿220的间隔之间提供多方向自由流动路径的网络，以用于沿水泥面板800下侧排水。所提供的腿220的圆柱形状和多方向流动路径减少残留水在水泥面板800中的集留，并同时允许水在屋顶表面水平上以多方向流动。由此，可获得更好的排水，甚至在下大雨时也是如此。通过将泡沫板包封在水泥壳体中，可防止水或湿气透过面板并弄湿泡沫板，从而避免了由于水或湿气含量而造成泡沫板变形或损坏的可能性。
泡沫板200的尺寸和厚度与成品水泥面板800的尺寸和厚度保持适当的比例，以获得令人满意的绝热效果。在一个实施方案中，泡沫板200的尺寸为18mm厚×480mm宽×480mm长。一种示例性聚苯乙烯泡沫板200的规格列于下表1中。
表1泡沫板的规格
  性质   测试方法   单位   典型值
  密度   kg/m3   40～50
  导热率  ASTM C518：1991   W/m °Kkcal/mm °K   0.022070.01897
  10％压缩强度  ASTM D 1621：   N/mm2   0.30
  (平均)  2000
  可燃性分级(平均燃烧速度)  ASTM C635：91   cm/min   10.0
  吸水性(平均)  ASTM C272：2001   ％   0.01
  热表面的温度   ℃   40.77
  冷表面的温度   ℃   19.95
  平均温度   ℃   30.36
一种示例性预混合的、自流平、高强度水泥浆体的组成列于下表2中。
表2水泥浆体的组成
  名称   CAS   比例
  波特兰水泥   65997-15-1   10-60％
  沙(结晶石英)   14808-60-7   10-60％
  助流剂，增塑剂   0-1％
  混凝土增强剂添加剂   250ml
一种示例性混凝土增强剂的规格列于下表3中。
表3混凝土增强剂的规格
 性质   单位   典型值
 固含量   ％   ＞40
 密度   kg/m3   1.16±0.04
 裂缝填充   mm   0.1-2
 吸收深度(针对等级20混凝土)   mm   1-8
 水生闪点   不可燃
 干燥时间   小时   1-3
  天气条件   ℃   10-50
  紫外线抗性   稳定
本领域技术人员将认识到，在不违背如广义描述的本发明精神和范围的情况下，可对如具体实施方案中所示的本发明进行多种变化和/或修改。因此，本实施方案的所有方面均应被视为举例说明，而非限制。

Claims (10)

1.一种用于生产复合面板的方法，包括：
将芯材板放置在模板中，所述芯材板具有顶表面、底表面和多个开口，所述多个开口从所述顶表面向所述底表面穿过所述芯材板，所述模板具有其内限定多个凹陷的基表面、从所述基表面向上延伸的多个销和在所述基表面的外周边缘周围翻转的裙料，其中所述芯材板通过所述多个销与所述基表面分开，并且与所述翻转的裙料隔开；
用粘性材料填充所述模板，所述粘性材料填充所述多个凹陷，填充所述芯材板中的所述多个开口并包围所述模板中的所述芯材板；和
使所述粘性材料硬化成包封所述芯材板的刚性外壳。
2.根据权利要求1所述的方法，还包括：
在将所述粘性材料倒入所述模板中之后，抹平所述粘性材料的顶表面以形成光滑表面。
3.根据权利要求1所述的方法，还包括：
在将所述粘性材料倒入所述模板中之后，将卵石倒入所述粘性材料的表面上。
4.根据权利要求1所述的方法，还包括：
在将所述粘性材料倒入所述模板中之后，将有色粉末倒入所述粘性材料的顶表面上。
5.根据权利要求1所述的方法，还包括：
在所述粘性材料硬化成所述刚性外壳之后，用材料覆盖所述刚性外壳的顶表面。
6.根据权利要求1所述的方法，还包括：
在所述粘性材料硬化成所述刚性外壳之后，从所述模板上取下所述复合面板。
7.根据权利要求1所述的方法，其中所述芯材板由聚苯乙烯泡沫制成。
8.根据权利要求1所述的方法，其中所述粘性材料是水泥混合物。
9.根据权利要求8所述的方法，还包括：
在将所述水泥混合物倒入所述模板中之前制备所述水泥混合物。
10.根据权利要求1所述的方法，还包括：
使穿过所述芯材板的多个开口中的每个开口对准所述模板中的所述多个凹陷的一个凹陷。
CN200880024349.1A 2007-05-18 2008-05-09 复合水泥面板 Expired - Fee Related CN101743365B (zh)

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