CN109577584A - 水泥基超高性能人造石保温隔音一体板生产及安装方法 - Google Patents

水泥基超高性能人造石保温隔音一体板生产及安装方法 Download PDF

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Publication number
CN109577584A
CN109577584A CN201811491610.0A CN201811491610A CN109577584A CN 109577584 A CN109577584 A CN 109577584A CN 201811491610 A CN201811491610 A CN 201811491610A CN 109577584 A CN109577584 A CN 109577584A
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China
Prior art keywords
nut
high performance
soundproof
heat preservation
artificial stone
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Pending
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CN201811491610.0A
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English (en)
Inventor
钟兵
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Individual
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Individual
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Priority claimed from CN201810096012.7A external-priority patent/CN108193858A/zh
Priority claimed from CN201810546706.6A external-priority patent/CN108409261A/zh
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Publication of CN109577584A publication Critical patent/CN109577584A/zh
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    • E04F19/02—Borders; Finishing strips, e.g. beadings; Light coves
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    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
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    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
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    • E04F13/0805—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and the wall
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Abstract

水泥基超高性能人造石保温隔音一体板生产及安装方法，包括采用超高性能混凝土的人造石板材、隔音材料、保温材料、金属连接件，人造石板材内埋设有不锈钢网片，不锈钢网片中设置有螺母，所述螺母端口与人造石板材的背部齐平，所述人造石板材与保温材料之间设有隔音材料。本发明充分利用螺母螺杆的螺合优势，用螺杆通过螺母和压板可将任意材质的保温材料、隔音板夹紧形成保温隔音一体板，克服现有保温一体板只能保温不能隔音的缺陷，并克服现有保温一体板只能用胶粘剂才能粘合保温材料的缺陷。克服了现有保温一体板只能用砂浆粘贴才能安装的缺隙。

Description

水泥基超高性能人造石保温隔音一体板生产及安装方法
技术领域
本发明涉及建筑装饰领域，尤其是一种水泥基超高性能人造石保温隔音一体板生产及安装方法。
背景技术
现有建筑在临近铁路、公路、机场、闹市区等噪音较大的区域，噪声会严重干扰人们的生活。甚至会引起身体疾患，为了阻隔噪音，人们对建筑的门采用了增加门的厚度或者在门的中间填充隔音材料等方法隔音。对建筑的窗户才用了密封性能好的塑钢门窗和双层中空玻璃，加大窗帘的厚度等方法隔音，对于建筑最主要的墙体隔音，一般较重的实体砖砌筑的墙体隔音效果最好，其次是钢筋混凝土浇筑的实心墙隔音效果次之，轻质砖隔音效果最差，即使是效果最好的实心墙在噪音较大的地方，也很难完全阻隔噪音传入室内，加之现代建筑越来越朝轻质化方向发展，轻质墙体砖使用也越来越广泛，为阻隔墙体噪音人们采用了以下方法：1.加大水泥砂浆在室内外墙体抹灰层的厚度，抹灰层越厚隔音效果越好；2.在室内外墙体加装采用石膏板、纤维水泥板、硅钙板等用夹芯板的方式在板材中间设置隔音材料形成带夹芯的隔音板，然后挂装在墙体形成隔音墙；3.对室内活动较多的地方，特别是卧式，单独形成全方位的隔音区域。以上方法均存在一定的弊端：1.加大抹灰层,增加了建筑的荷载、增加了建筑的成本、再厚的砂浆比专门的隔音材料效果差很多；2.夹芯板，石膏板耐水性差、易受潮膨胀变形；水泥纤维板、硅钙板重量大，挂装成本高，吸水率大，易膨胀变形；3.室内独立隔音，安装费用高、成本大、不能全方位隔音。上述方法虽然一定程度减少噪音，但整个建筑外墙的保温和装饰同样没有解决，在现代建筑对保温节能越来越严格的情况下，如何解决建筑外墙的装饰、保温、隔音越来越引起人们的重视。
经检索发现为解决上述问题，在专利（专利号：201620351230.7）一种带保温的纳米水泥基高强人造平板石材中，发明人利用水泥基材料从液体到固体的特性，预埋了可以外挂连接的螺母，在板材凝固后螺母与板材融为一体，通过螺杆螺母的螺合优势将板材与保温材料和直金属挂条相互夹紧形成保温一体板，克服了天然石材板、陶瓷仿石板、水泥纤维板、硅钙板只能用胶粘剂粘连保温材料的缺隙。安装时，在与板材相互连接的直金属挂条的另一端挂条通孔内植入膨胀螺栓，与墙体固定连接。克服现有保温一体板只能用砂浆粘贴的缺隙，但板材的配置采用普通高强配方工艺生产存在强度低、密实度低、耐候性差、吸水率高、抗冻融性差等缺点，预埋的螺母由于独立摆放，挂装强度较低，而且没能解决隔音的问题。
发明内容
本发明的目的在于提供水泥基超高性能人造石保温隔音一体板生产及安装方法，以解决上述背景技术中提出的问题。
为实现上述目的，本发明提供如下技术方案：一种水泥基超高性能人造石保温隔音一体板，包括采用超高性能混凝土（UHPC）的人造石板材、隔音材料、保温材料、金属连接件，其特征在于所述人造石板材内埋设有不锈钢网片，不锈钢网片中设置有螺母，所述螺母的端口与人造石板材的背部齐平；
所述人造石板材与保温材料之间设有隔音材料，所述保温材料上压制有金属连接件，金属连接件包括直金属条，直金属条两端分别设有至少一个螺杆通孔，直金属条其中一端螺杆通孔穿置有螺杆，所述螺杆还依次穿过保温材料、隔音材料的通孔后与人造石板材上的螺母螺合连接。
作为优选，所述保温材料上还设有压板，所述压板中间设有通孔，所述螺杆依次穿过压板通孔、保温材料、隔音材料与人造石板材上的螺母螺合连接。
作为优选，所述不锈钢网片与螺母以焊接方式连接。
作为优选，所述螺母为不锈钢螺母。
作为优选，所述螺杆外端螺合有紧固螺母，紧固螺母将直金属条、压板压制在人造石保温隔音一体板背部。
作为优选，所述超高性能混凝土（UHPC）包括525及525以上的高标号水泥、硅灰和矿渣粉、6mm粒径以下砂石骨料、聚羧酸高效减水剂，上述组分加入适量的水按水胶比不超过0.25的比例混凝而成。
作为优选，所述6mm粒径以下砂石骨料为4～6目米石、10～20目米石、40～80目米石、80～120目石英粉、800～1200目石英粉中的一种或多种组合。
作为优选，所述超高性能混凝土包括以下质量份数的组分525及525以上的白色硅酸盐水泥100份、硅灰8～15份、矿渣粉10～30份、4～6目米石50～80份、10～20目米石50～100份、40～80目米石20～50份、80～120目石英粉5～10份、800～1200目石英粉5～10份、聚羧酸高效减水剂0.5～2份、憎水粉0.2～1.0份、氧化铁颜料0～5份、粉煤灰0～30份、纳米二氧化硅0.5～5份、纳米二氧化钛0.5～5份、纳米碳酸钙0.5～5份，上述组分按水胶比0.18～0.22的比例加入适量的水，制作方法包括以下步骤：
1.制板设备的准备：制板设备包括高频振动器，不小于10kg/cm2压力的液压机，抽真空至-0.08MPa压力以下的真空设备，根据制板规格确定料框和压板尺寸；
2.将搅拌好的浆料投入涂抹好脱模剂的料框内，抹平并打开高频振动器，振动10～15秒后，在浆料内铺放带螺母的不锈钢网片，最后在浆料上铺放有吸水性的隔离布；
3.打开液压机按不小于10kg/cm2压力压制15～30秒，并同时抽真空至-0.08MPa以下；
4.取出隔离布，将压好的板材用托板运送至蒸汽养护室养护；
5.将养护好的板材定制成标准厚度，根据不同的板面效果要求，用包括磨光机、喷砂机、火烧面机、水冲面机、荔枝面机中的一种或多种组合设备处理成所需表面效果，得到本发明人造石板材；
6.清理板材、用烘干机烘干，在人造石板材外表面喷涂防护剂。
水泥基超高性能人造石保温隔音一体板的安装方法：人造石板材通过金属连接件以干挂加湿贴方式安装在墙体上，用少量砂浆点式抹在保温材料背部；将膨胀螺栓穿过直金属条的另一端螺杆通孔向墙体植入；用皮锤敲击人造石板材表面至要求平整度；拧紧膨胀螺栓将直金属条固定于墙体，完成人造石板材安装。
本发明采用超高性能混凝土（UHPC）所必需的基本材料和配方工艺为基础要求，添加可以增加抗拆强度的不锈钢网片，并以强振、强压、抽真空为主要制板方法。强压、抽真空是现有建筑桥梁等制作超高性能混凝土很难达到的制作条件；强压结合吸水布能挤出和吸走板材中的水份；抽真空能抽出板材中的气体和多余的水份，两者能使水份减少20%以上，能使板材的密实度更高，从而更能达到超高性能混凝土水胶越低、强度越高的原理条件，整板连接在一起的不锈钢网片比超高性能混凝土所必需的分散性的钢纤维具有更好的连接支撑的骨架作用，使板材的骨料与网片完全融为一体，不锈钢丝的刚性和韧性，使板材在很薄的情况下也不会出现断裂脱落的现象，本发明板材厚度在10mm左右，从而使板材重量大大减轻。本发明制作的板材具有超高性能混凝土所具备的超高强、高韧性、高耐久的显著特点，比普通强度混凝土的各项性能指标优越数倍以上，从而完全克服发明人原有水泥基板材强度低、密度低、抗拆性差、耐候差、抗冻融性差等缺隙。
本发明用于外挂连接的螺母与不锈钢网片焊接在一起，与不锈钢网片一起铺设在板材背部浆料中，凝固后完全成为一个整体，不锈钢材质的网片在安装时，切割成任意大小也不会锈蚀，克服普通金属材质的网片和钢纤维易锈蚀的缺隙；连接在一起的螺母挂装时，受力点均与整个板材连接，具有极高的挂装强度，克服了原有水泥基人造石独立摆放螺母，独立受力挂装的挂装强度低的缺隙。本发明的螺母具有抗锈蚀的优点，与板材背部平齐的螺母便于流水线加工和运输。
本发明充分利用螺母螺杆的螺合优势，用螺杆通过螺母和压板可将任意材质的保温材料、隔音板夹紧形成保温隔音一体板，克服现有保温一体板只能保温不能隔音的缺陷，并克服现有保温一体板只能用胶粘剂才能粘合保温材料的缺陷。安装时，只需将保温隔音一体板与直金属条一端固定连接，直金属条另一端与植入墙体膨胀螺栓固定，即可完成安装，克服了现有保温一体板只能用砂浆粘贴才能安装的缺隙。
本发明以废弃的各色石米和高标号白色硅酸盐水泥为主要原料，加入可调制各种颜色的氧化铁颜料，并在超高性能混凝土工艺的基础上，添加了多种纳米材料使板材在室外环境下具有更好的耐候性和耐久性。板材表面采用天然石材处理表面的剥离工艺原理，利用石材处理表面的相同设备和工艺，可制作出近千种颜色和表面效果，完全达到天然石材装饰效果，并克服天然石材因自然形成而产生的色差问题。
本发明无需开山采石，无需高温烧制，无化学反应，废弃料脱水烘干后可重复使用或者制作其它建材，完全达到零污染、零排放。克服了天然石材开山采石破坏环境，陶瓷高温烧制浪费能源，陶土开采破坏环境产生污染的弊端，是一项利国利民的技术。
附图说明
图1为本发明人造石保温隔音一体板的结构示意图；
图2为本发明中压板应用的结构示意图；
图3为本发明干挂加湿贴结构的示意图；
图4为本发明中T型螺母在板材中应用的结构示意图。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
如图1所示，水泥基超高性能人造石保温隔音一体板，包括采用超高性能混凝土（UHPC）的人造石板材2、隔音材料3、保温材料4、金属连接件，人造石板材2内埋设有不锈钢网片7，不锈钢网片中设置有螺母11，所述螺母11的数量为两个及两个以上。所述螺母11的端口与人造石板材2的背部齐平，所述人造石板材2与保温材料4之间设有隔音材料3。隔音材料3可以是玻璃棉毡、隔音毡、隔音毯、岩棉、聚氨酯隔音板等。保温材料4可以是聚氨酯外墙保温板、岩棉保温板、酚醛保温板、EPS保温板、STP保温板、XPS保温板。
保温材料4的上压制有金属连接件，所述金属连接件包括直金属条6，所述直金属条6两端分别设有至少一个螺杆通孔，直金属条6其中一端螺杆通孔穿置有螺杆10，该螺杆10还依次穿过保温材料、隔音材料的通孔后与人造石板材上的螺母螺合连接。上述螺杆10可以是有蘑菇头、平头、圆锥头、六角的。当然蘑菇头等大头可以直接将金属连接件压制在人造石板材2背部。
实施例一
板面颜色：黄色；高光面；规格：600*900mm；厚度10mm。
1.原料配置：525白色硅酸盐水泥100份、硅灰8份、矿渣粉20份、4～6目黄色米石60份、4～6目黑色米石20份、10～20目黄色米石50份、40～80目白色米石20份、80～120目石英粉5份、800～1200目石英粉5份、聚羧酸高效减水剂0.8份、憎水粉0.6份、氧化铁黄色颜料2份、粉煤灰10份、纳米二氧化钛1份、纳米二氧化硅1.5份、纳米碳酸钙2.5份。
2.将上述干粉料，通过干粉设备搅拌均匀制作干粉，分袋包装。
3.将干粉按比例加入高效减水剂和水搅拌10分钟，上述所有组分加入适量的水按水胶比0.2的比例混凝而成。
4.准备强振、强压、抽真空设备，准备600*900mm模框，并在模框内喷涂脱模剂。
5.将搅拌好的浆料投入模框内，找平并打开高频振动器，振动10～15秒。
6.将振动好的浆料，按确定位置铺放不锈钢网片1、螺母2和隔离布。
7.打开液压机将相同规格的压板对准模框，压力500吨压制20秒并同时打开真空机抽真空至～0.08MPa，两者时间同步。
8.取出隔离布，将压制好的人造石板材2，用托板，送至蒸汽养护室养护。
9.将养护好的板材用定厚机定制成标准厚度。
10.用石材连续磨光机磨光。
11.烘干并喷涂表面防护剂，得到人造石板材。
12.在人造石板材上依次安装隔音材料和保温材料，隔音材料为隔音毡，保温材料为岩棉保温板。
13.在墙体施工放线做好标记。
14.如图2-3所示，保温材料4的上还可以设有压板5，压板为金属、塑料、木板等有一定硬度材质制作的压板。所述压板5上设有通孔，所述压板5上设有直金属条6。通孔穿置有螺杆10，螺杆10依次穿过压板通孔、保温材料4、隔音材料3与人造石板材2上的螺母11螺合连接。
15.若螺杆10是无头螺杆的，所述螺杆10外端螺合有紧固螺母12，紧固螺母12将直金属条6、压板5压制在人造石保温隔音一体板1背部。当然，紧固螺母12可以直接将压板5压制在人造石板材2背部。用少量砂浆点式抹在保温材料背部；砂浆起到定位厚度作用，将膨胀螺栓8穿过直金属条6的另一端螺杆通孔向墙体9植入；用皮锤敲击人造石板材表面至要求平整度，拧紧膨胀螺栓8将直金属条固定于墙体9，完成人造石保温隔音一体板1安装。
实施例二
板面颜色：红色；火烧面；规格：600*600mm；厚度11mm。
1.原料配置：525白色硅酸盐水泥100份、硅灰10份、矿渣粉30份、4～6目红色米石80份、4～6目黑色米石20份、10～20目红色米石80份、40～80目白色米石40份、80～120目石英粉8份、800～1200目石英粉10份、聚羧酸高效减水剂2份、憎水粉1.0份、氧化铁红色颜料5份、粉煤灰20份、纳米二氧化钛2份、纳米二氧化硅3份、纳米碳酸钙1.5份、上述组分加入适量的水按水胶比0.22的比例混凝而成。
2.颜料为红色氧化铁颜料，米石为红色，其它规格同实施例一。
3.模框规格为600*600mm。
4.隔音材料为聚氨酯泡沫塑料，保温材料为酚醛保温板。
5.压力400吨压制15秒。
6.表面处理用石材火烧面机烧面形成火烧面。
7.将振动好的浆料，按确定位置铺放焊接有螺母2的不锈钢网片1和隔离布，螺母2可以为不锈钢螺母；不锈钢螺母可与不锈钢网片1焊接在一起。也可以如图4所示，不锈钢螺母可以是T型螺母211，T型不锈钢螺母211穿过不锈钢网片1与板材本体3的背部齐平。
8.其制作方式及步骤同实施例一。
实施例三
板面颜色：黑色；水冲面；规格500*700mm；厚度9mm。
1.原料配置：525及525以上的白色硅酸盐水泥100份、硅灰15份、矿渣粉10份、4～6黑色目米石80份、10～20黑色目米石100份、40～80目黑色米石50份、80～120目石英粉10份、800～1200目石英粉8份、聚羧酸高效减水剂0.5份、憎水粉0.2份、氧化铁黑色颜料1份、粉煤灰30份、纳米二氧化钛3份、纳米二氧化硅3.5份、纳米碳酸钙4.5份，上述组分加入适量的水按水胶比0.18的比例混凝而成。
2.模框规格为500*700mm。
3.压力350吨压制30秒。
4.隔音材料为隔音毯，保温材料为XPS保温板。
5.板材表涂刷缓凝剂，初凝后用高压水枪冲面形成水冲面。
6.其制作方式及步骤同实施例一。
对于本领域技术人员而言，显然本发明不限于上述示范性实施例的细节，而且在不背离本发明的精神或基本特征的情况下，能够以其他的具体形式实现本发明。因此，无论从哪一点来看，均应将实施例看作是示范性的，而且是非限制性的，本发明的范围由所附权利要求而不是上述说明限定，因此旨在将落在权利要求的等同要件的含义和范围内的所有变化囊括在本发明内。不应将权利要求中的任何附图标记视为限制所涉及的权利要求。
此外，应当理解，虽然本说明书按照实施方式加以描述，但并非每个实施方式仅包含一个独立的技术方案，说明书的这种叙述方式仅仅是为清楚起见，本领域技术人员应当将说明书作为一个整体，各实施例中的技术方案也可以经适当组合，形成本领域技术人员可以理解的其他实施方式。

Claims (9)

1.一种水泥基超高性能人造石保温隔音一体板，包括采用超高性能混凝土的人造石板材、隔音材料、保温材料、金属连接件，其特征在于所述人造石板材内埋设有不锈钢网片，不锈钢网片中设置有螺母，所述螺母的端口与人造石板材的背部齐平；
所述人造石板材与保温材料之间设有隔音材料，所述保温材料上压制有金属连接件，金属连接件包括直金属条，直金属条两端分别设有至少一个螺杆通孔，直金属条其中一端螺杆通孔穿置有螺杆，所述螺杆还依次穿过保温材料、隔音材料的通孔后与人造石板材上的螺母螺合连接。
2.根据权利要求1所述的一种水泥基超高性能人造石保温隔音一体板，其特征在于所述保温材料上还设有压板，所述压板中间设有通孔，所述螺杆依次穿过压板通孔、保温材料、隔音材料与人造石板材上的螺母螺合连接。
3.根据权利要求1所述的一种水泥基超高性能人造石保温隔音一体板，其特征在于所述不锈钢网片与螺母以焊接方式连接。
4.根据权利要求3所述的一种水泥基超高性能人造石保温隔音一体板，其特征在于所述螺母为不锈钢螺母。
5.根据权利要求2所述的一种水泥基超高性能人造石保温隔音一体板，其特征在于所述螺杆外端螺合有紧固螺母，紧固螺母将直金属条、压板压制在人造石保温隔音一体板背部。
6.根据权利要求1或2或3所述的一种水泥基超高性能人造石保温隔音一体板的生产方法，其特征在于所述超高性能混凝土包括525及525以上的高标号水泥、硅灰和矿渣粉、砂石骨料、聚羧酸高效减水剂，上述组分加入适量的水按水胶比不超过0.25的比例混凝而成。
7.根据权利要求5所述的一种水泥基超高性能人造石保温隔音一体板，其特征在于所述砂石骨料为6mm粒径以下砂石骨料，所述砂石骨料为4～6目米石、10～20目米石、40～80目米石、80～120目石英粉、800～1200目石英粉中的一种或多种组合。
8.根据权利要求5所述的一种水泥基超高性能人造石保温隔音一体板的生产方法，其特征在于所述超高性能混凝土包括以下质量份数的组分525及525以上的白色硅酸盐水泥100份、硅灰8～15份、矿渣粉10～30份、4～6目米石50～80份、10～20目米石50～100份、40～80目米石20～50份、80～120目石英粉5～10份、800～1200目石英粉5～10份、聚羧酸高效减水剂0.5～2份、憎水粉0.2～1.0份、氧化铁颜料0～5份、粉煤灰0～30份、纳米二氧化硅0.5～5份、纳米二氧化钛0.5～5份、纳米碳酸钙0.5～5份，上述组分按水胶比0.18～0.22的比例加入适量的水，制作方法包括以下步骤：
（1）制板设备的准备：制板设备包括高频振动器，不小于10kg/cm2压力的液压机，抽真空至-0.08MPa压力以下的真空设备，根据制板规格确定料框和压板尺寸；
（2）将搅拌好的浆料投入涂抹好脱模剂的料框内，抹平并打开高频振动器，振动10～15秒后，在浆料内铺放带螺母的不锈钢网片，最后在浆料上铺放有吸水性的隔离布；
（3）打开液压机按不小于10kg/cm2压力压制15～30秒，并同时抽真空至-0.08MPa以下；
（4）取出隔离布，将压好的板材用托板运送至蒸汽养护室养护；
（5）将养护好的板材定制成标准厚度，根据不同的板面效果要求，用包括磨光机、喷砂机、火烧面机、水冲面机、荔枝面机中的一种或多种组合设备处理成所需表面效果，得到本发明人造石板材。
9.根据权利要求1或2所述的一种水泥基超高性能人造石保温隔音一体板的安装方法，其特征在于所述人造石板材通过金属连接件以干挂加湿贴方式安装在墙体上，用少量砂浆点式抹在保温材料背部；将膨胀螺栓穿过直金属条的另一端螺杆通孔向墙体植入；用皮锤敲击人造石板材表面至要求平整度；拧紧膨胀螺栓将直金属条固定于墙体，完成人造石板材安装。
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