Production process and structure of double-sided prefabricated thermal insulation composite shear wall plate

Abstract

This invention discloses a production process and structure for double-sided prefabricated insulated composite shear wall panels. The production process includes the following steps: laying out lines on a mold platform; installing side molds on the mold platform; tying the reinforcing bars of the inner leaf wall; tying the truss reinforcing bars or reinforcing cage; pouring the inner leaf wall concrete; pre-drilling reserved holes for the insulation connectors at corresponding positions on the insulation board according to the design drawings of the insulation connectors; passing the insulation connectors through the reserved holes on the insulation board and fitting them with a support plate; inserting the insulation connectors with the insulation board attached into the inner leaf wall concrete before the initial setting of the inner leaf wall concrete; tying the reinforcing bars of the outer leaf wall on the insulation board; pouring the outer leaf wall concrete; and removing the mold after both the outer and inner leaf wall concretes have reached their strength to obtain the double-sided prefabricated insulated composite shear wall panels. This invention requires minimal investment in production equipment and can achieve the production of double-sided prefabricated insulated composite shear wall panels on a standard production line, with strong versatility of the assembly line.

Description

Technical Field

[0001] This invention relates to the field of prefabricated buildings, specifically to a production process and structure for a double-sided prefabricated insulated composite shear wall panel. Background Technology

[0002] Currently, there are various systems for the prefabrication and assembly of shear walls in prefabricated buildings, with the main difference being the prefabrication and connection methods of the shear walls. In China, the main systems used are the longitudinal steel reinforcement sleeve grouting connection system, the prefabricated formwork structure system, and the double-sided prefabricated composite shear wall cast-in-place system. With the development of prefabricated buildings, the technology of double-sided prefabricated composite shear walls has gradually gained market recognition. Currently, common double-sided composite shear walls connect the inner and outer leaf walls with truss reinforcement, with the hollow section serving as a reserved cast-in-place layer. The inner and outer leaf walls act as formwork during on-site casting to resist the lateral pressure of the concrete. With increasing societal demands for building energy conservation, when double-sided prefabricated composite shear walls are used as exterior walls, insulation boards need to be added between the two sides to meet energy conservation requirements, forming a double-sided prefabricated insulated composite shear wall panel. Double-sided precast insulated composite shear wall panels have advantages such as simple on-site hoisting operations, low lifting requirements for hoisting machinery, good structural integrity, and low cost. However, the production of double-sided precast insulated composite shear wall panels currently faces the following technological challenges: 1. A production line with a mold table flipping function must be used, and most of the equipment is imported from Europe, resulting in high equipment costs; 2. The inner and outer leaf walls are produced on different mold tables, requiring two mold tables for each double-sided composite panel, which significantly occupies mold tables and workstations; 3. The production of the inner and outer leaf walls of a double-sided composite panel requires two curing processes, reducing the efficiency of the curing kiln; 4. It takes two days to complete one double-sided composite panel, resulting in a long production cycle and low efficiency.

[0003] The above shortcomings need to be improved. This invention does not require a flipping device and can double the production efficiency. Summary of the Invention

[0004] In order to overcome the shortcomings of existing technologies, this invention provides a production process and structure for double-sided prefabricated insulated composite shear wall panels.

[0005] A production process for a double-sided prefabricated insulated composite shear wall panel, characterized by the following steps:

[0006] Step S1: Lay the lines on the mold table;

[0007] Step S2: Install the side mold on the mold platform;

[0008] Step S3: Tie the reinforcing bars of the inner leaf wall;

[0009] Step S4: Tie the truss reinforcement bars or reinforcement cage;

[0010] Step S5: Pour the inner leaf wall concrete;

[0011] Step S6: Drill pre-drilled holes for the insulation connector at the corresponding positions on the insulation board according to the design drawing of the insulation connector. The diameter of the pre-drilled holes for the insulation connector matches the diameter of the first rubber sleeve on the insulation connector.

[0012] Step S7: Pass the insulation connector through the pre-drilled hole on the insulation board, and insert the support plate into the insulation connector so that the support plate is locked at the bottom of the first rubber sleeve. The first rubber sleeve and the support plate lock the insulation board in place.

[0013] Step S8: Before the inner leaf wall concrete has initially set, insert the insulation connector with the insulation board attached into the inner leaf wall concrete.

[0014] Step S9: Tie the reinforcing bars of the outer leaf wall to the insulation board, pour the outer leaf wall concrete, and remove the formwork after the outer leaf wall concrete and the inner leaf wall concrete have reached their strength to obtain the double-sided prefabricated insulated composite shear wall panel.

[0015] According to the present invention based on the above scheme, the feature is that it further includes step S10, sending the double-sided prefabricated insulated composite shear wall panel into a curing kiln for curing.

[0016] According to the present invention based on the above scheme, the step S6 further includes drilling pre-drilled holes for the pre-embedded hanging parts on the insulation board.

[0017] Furthermore, prior to step S9, step S81 is included, in which the embedded hanging member is passed through the pre-reserved hole of the embedded hanging member on the insulation board, so that one end of the embedded hanging member is inserted into the inner leaf wall concrete, and the other end of the embedded hanging member protrudes from the upper surface of the insulation board, the length of the protruding part is not greater than the thickness of the inner leaf wall.

[0018] According to the present invention based on the above scheme, the lower end of the thermal insulation connector passes through the inner leaf wall concrete and contacts the formwork.

[0019] According to the present invention based on the above scheme, the side mold is provided with a support platform on its inner side, and the support platform supports the bottom edge of the insulation board.

[0020] According to the present invention based on the above scheme, the characteristic is that, in step S3, the lower chord of the truss reinforcement or the bottom of the reinforcement cage is located inside the inner leaf wall.

[0021] On the other hand, a production structure for a double-sided prefabricated insulated composite shear wall panel is characterized by comprising a mold platform, side molds, and a double-sided prefabricated insulated composite shear wall panel. The side molds are vertically fixed on the mold platform. The double-sided prefabricated insulated composite shear wall panel is disposed within the space enclosed by the mold platform and the side molds. The double-sided prefabricated insulated composite shear wall panel includes an inner leaf wall, an insulation board, and an outer leaf wall arranged sequentially from bottom to top. An insulation connector passes sequentially through the outer leaf wall, the inner leaf wall, and the insulation board, and is fixed to the outer leaf wall, the inner leaf wall, and the insulation board. A first rubber sleeve and a support plate are fitted on the insulation connector. The insulation connector is connected to the insulation board through the first rubber sleeve. The support plate is connected to a retaining ring at the lower end of the first rubber sleeve, and the support plate supports the bottom of the insulation board.

[0022] According to the present invention based on the above scheme, the lower end of the thermal insulation connector passes through the inner leaf wall and contacts the mold platform.

[0023] According to the present invention based on the above scheme, the double-sided prefabricated insulated composite shear wall panel further includes embedded hanging components, which are disposed within the inner leaf wall, the insulation board, and the outer leaf wall.

[0024] Furthermore, a second rubber sleeve is fitted onto the embedded hanging component, and the second rubber sleeve matches the reserved hole of the embedded hanging component on the insulation board.

[0025] Furthermore, the embedded lifting component is a sheet-like rod.

[0026] Furthermore, the material of the pre-embedded hanging component is glass fiber reinforced resin, basalt, or stainless steel.

[0027] According to the present invention based on the above scheme, the side mold is provided with a support platform on its inner side, and the support platform supports the bottom edge of the insulation board.

[0028] According to the present invention based on the above scheme, the feature is that a truss reinforcement or a reinforcement cage is provided between the inner leaf wall and the insulation board.

[0029] Furthermore, the lower chord of the truss reinforcement or the bottom of the reinforcement cage is located within the inner leaf wall.

[0030] The beneficial effects of this invention are as follows:

[0031] (1) The production equipment investment is small. This invention only requires a regular production line and does not require a mold turning equipment to realize the production of double-sided prefabricated insulated composite shear wall panels. The production line has strong versatility and requires little investment in equipment. Most prefabricated component factories have the production conditions.

[0032] (2) Small space occupation. Traditional production process requires turning over and requires at least two molds. This invention only needs one mold to realize the production of double-sided prefabricated insulated composite shear wall panels, which can save 50% of production space.

[0033] (3) All production steps can be completed in one day, with high production efficiency. When using the flipping process, it is necessary to divide it into A side and B side. Before the concrete of B side produced on the second day has solidified, A side produced on the first day needs to be placed on B side for composite. In order to flip A side, it is necessary to steam curing for at least one day before proceeding to the next process, depending on the actual situation. However, this invention can complete all processes on the same day and directly enter the curing stage, shortening the two-day production process to one day, greatly improving work efficiency. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the structure of the present invention;

[0035] Figure 2 This is a structural schematic diagram of the double-sided prefabricated insulated composite shear wall panel of the present invention;

[0036] Figure 3 This is a schematic diagram showing the connection between the side mold and the mold table of the present invention;

[0037] Figure 4 This is a schematic diagram of the structure of the thermal insulation connector of the present invention;

[0038] Figure 5 This is a schematic diagram of the structure of the embedded lifting component of the present invention;

[0039] Figure 6 This is a structural schematic diagram of the pre-embedded lifting component of the present invention from another perspective;

[0040] In the diagram,

[0041] 1. Mold table;

[0042] 2. Side mold; 21. Support platform;

[0043] 3. Double-sided prefabricated insulated composite shear wall panel; 31. Inner leaf wall; 32. Insulation board; 33. Outer leaf wall; 34. Insulation connector; 35. Embedded hanger; 36. Truss reinforcement; 311. Reinforcing mesh; 341. First rubber sleeve; 342. Support plate; 351. Second rubber sleeve. Detailed Implementation

[0044] The present invention will now be further described with reference to the accompanying drawings and embodiments:

[0045] like Figures 1-4As shown, a production structure for a double-sided prefabricated insulated composite shear wall panel includes a mold platform 1, side molds 2, and a double-sided prefabricated insulated composite shear wall panel 3. The side molds 2 are vertically fixed on the mold platform 1, and the double-sided prefabricated insulated composite shear wall panel 3 is arranged within the space enclosed by the mold platform 1 and the side molds 2. The double-sided prefabricated insulated composite shear wall panel 3 includes an inner leaf wall 31, an insulation board 32, and an outer leaf wall 33 arranged sequentially from bottom to top. An insulation connector 34 passes through the outer leaf wall 33, the inner leaf wall 32, and the insulation board 31 in sequence and is fixed to them. The lower end of the insulation connector 34 passes through the inner leaf wall 31 and contacts the mold platform 1, serving as a support to bear the upper load and simultaneously controlling the hollow thickness of the double-sided prefabricated insulated composite shear wall panel 3. The insulation connector 34 is fitted with a first rubber sleeve 341 and a support plate 342. The insulation connector 34 is connected to the insulation board 32 through the first rubber sleeve 341. The support plate 342 is connected to a specially made retaining ring (not shown in the figure, the same below) at the lower end of the first rubber sleeve 341. The support plate 342 supports the bottom of the insulation board 32. The weight of the outer leaf wall 33 is transferred to the support plate 342 through the insulation board 32, and then transferred to the vertical insulation tie member 34 by the special retaining ring of the support plate 342 and the first rubber sleeve 341. The insulation tie member 34 is supported on the mold table 1, thereby forming a cavity structure between the inner leaf wall 31 and the insulation board 32. A support platform 21 is provided on the inner side of the side mold 2. The support platform 21 supports the bottom edge of the insulation board 32 and bears the weight of the upper edge of the insulation board 32. The present invention utilizes the side mold 2, the thermal insulation connector 34, and the support plate 342 to bear the construction load during the production of the inner leaf wall 31, ensuring the hollow thickness of the double-sided prefabricated thermal insulation composite shear wall panel, thereby achieving the goal of continuous production of thermal insulation double-sided composite shear wall without flipping.

[0046] like Figure 5 , Figure 6 As shown, in one embodiment, the double-sided prefabricated insulated composite shear wall panel 3 further includes embedded lifting members 35. The embedded lifting members 35 are disposed within the inner leaf wall 31, the insulation board 32, and the outer leaf wall 33. The embedded lifting members 35 are used for demolding and installation lifting of the double-sided prefabricated insulated composite shear wall panel 3, and can ensure uniform stress distribution on the inner and outer leaf walls. The embedded lifting members 35 can be ordinary metal rods or insulation connectors 34.

[0047] Furthermore, a second rubber sleeve 351 is fitted onto the embedded hanger 35. The second rubber sleeve 351 matches the reserved hole for the embedded hanger on the insulation board 32, ensuring a tight connection between the insulation board 32 and the embedded hanger 35 to prevent grout leakage. The embedded hanger 35 is a sheet-like rod with an approximately rectangular cross-section. The material of the embedded hanger 35 can be glass fiber reinforced plastic, basalt, or stainless steel. This application does not impose any restrictions on this, and those skilled in the art can choose according to their own needs.

[0048] In one embodiment, a truss reinforcement 36 or a reinforcement cage is provided between the inner leaf wall 31 and the insulation board 32. The bottom chord of the truss reinforcement 36 or the bottom of the reinforcement cage is located inside the inner leaf wall 31. The thickness of the double-sided prefabricated insulated composite shear wall panel 3 is limited by the truss reinforcement 36 or the reinforcement cage.

[0049] In one embodiment, the mold platform 1 and the side mold 2 are made of metal, plastic or wood, etc. This application does not limit this, and those skilled in the art can choose according to their own needs.

[0050] In one embodiment, both the inner leaf wall 31 and the outer leaf wall 33 are formed by concrete casting, and both the inner leaf wall 31 and the outer leaf wall 33 are provided with steel mesh 311.

[0051] The production process of the above-mentioned double-sided prefabricated insulated composite shear wall panel 3 includes the following steps:

[0052] Step S1: Lay out the outline of the wall panel, the opening, and the position of the embedded parts on the mold table 1.

[0053] Step S2: Install the side mold 2 on the mold table 1. The side mold 2 is vertically fixed on the mold table 1.

[0054] Step S3: Tie the reinforcing bars of the inner leaf wall 31.

[0055] Step S4: Tie the truss reinforcement 36 or the reinforcement cage. The bottom chord of the truss reinforcement 36 or the bottom of the reinforcement cage is located inside the inner leaf wall 31, and the thickness of its protective layer is controlled.

[0056] Step S5: Pour the inner leaf wall concrete as required and vibrate it to ensure it is compacted.

[0057] Step S6: According to the design drawing of the insulation connector 34, pre-drill the reserved holes for the insulation connector and the reserved holes for the pre-embedded hangers at the corresponding positions on the insulation board 32. The diameter of the reserved holes for the insulation connector matches the diameter of the first rubber sleeve 341 on the insulation connector 34 to ensure that the insulation board 32 and the insulation connector 34 are tightly connected and leak-proof.

[0058] Step S7: Pass the insulation connector 34 through the insulation connector pre-drilled hole on the insulation board 32, and put the support plate 342 into the insulation connector 34 so that the support plate 342 is stuck at the bottom end of the first rubber sleeve 341. Under the combined action of the first rubber sleeve 341 and the support plate 342, the insulation board 32 is stuck.

[0059] Step S8: Before the inner leaf wall concrete initially sets, insert the insulation connector 34, which holds the insulation board 32, into the inner leaf wall concrete. The lower end of the insulation connector 34 passes through the inner leaf wall concrete and contacts the formwork 1, serving as a support to bear the upper load and controlling the hollow thickness of the composite wall panel. Simultaneously, a support platform 21 is provided on the inner side of the side formwork 2. When the insulation connector 34, holding the insulation board 32, is inserted into the inner leaf wall concrete, the support platform 21 supports the bottom edge of the insulation board 32, bearing the upper weight of the edge of the insulation board 32.

[0060] Step S9: Pass the pre-embedded hanger 35 through the pre-embedded hanger reserved hole on the insulation board 32, so that one end of the pre-embedded hanger 35 is inserted into the inner leaf wall concrete, and the other end of the pre-embedded hanger 35 protrudes from the upper surface of the insulation board, and the length of the protruding part is not greater than the thickness of the inner leaf wall 31.

[0061] Step S10: Tie the reinforcing bars of the outer leaf wall 33 to the insulation board 32, pour the outer leaf wall concrete, vibrate and finish the surface. After the outer leaf wall concrete and the inner leaf wall concrete reach the strength, remove the formwork to obtain the double-sided prefabricated insulated composite shear wall panel 3.

[0062] Step S11: Send the double-sided prefabricated insulated composite shear wall panel 3 into the curing kiln for curing.

[0063] It should be understood that those skilled in the art can make improvements or modifications based on the above description, and all such improvements and modifications should fall within the protection scope of the appended claims.

[0064] The present invention has been described above with reference to the accompanying drawings. Obviously, the implementation of the present invention is not limited to the above-described manner. Any improvements made using the inventive concept and technical solution of the present invention, or the direct application of the inventive concept and technical solution of the present invention to other situations without modification, are all within the protection scope of the present invention.

Claims

1. A production structure for a double-sided prefabricated insulated composite shear wall panel, comprising a mold platform, side molds, and a double-sided prefabricated insulated composite shear wall panel, wherein the side molds are vertically fixed on the mold platform, and the double-sided prefabricated insulated composite shear wall panel is disposed within the space enclosed by the mold platform and the side molds, the double-sided prefabricated insulated composite shear wall panel comprising, from bottom to top, an inner leaf wall, an insulation board, and an outer leaf wall, wherein an insulation connector passes sequentially through the outer leaf wall, the inner leaf wall, and the insulation board, and is connected to the outer leaf wall, the inner leaf wall, and the insulation board. The insulation board is fixed, and the insulation connector is fitted with a first rubber sleeve and a support plate. The insulation connector is connected to the insulation board through the first rubber sleeve. The support plate is connected to the retaining ring at the lower end of the first rubber sleeve. The support plate supports the bottom of the insulation board. The lower end of the insulation connector passes through the inner leaf wall and contacts the mold table. The pre-embedded hanger is set in the inner leaf wall, the insulation board and the outer leaf wall. The pre-embedded hanger is fitted with a second rubber sleeve, and the second rubber sleeve matches the pre-embedded hanger reserved hole on the insulation board. The production process of the double-sided prefabricated insulated composite shear wall panel includes the following steps: Step S1: Lay the lines on the mold table; Step S2: Install the side mold on the mold platform; Step S3: Tie the reinforcing bars of the inner leaf wall; Step S4: Tie the truss reinforcement or the reinforcement cage, with the bottom chord of the truss reinforcement or the bottom of the reinforcement cage located inside the inner leaf wall; Step S5: Pour the inner leaf wall concrete; Step S6: According to the design drawing of the insulation connector, pre-drill the reserved holes for the insulation connector and the reserved holes for the embedded hangers in the corresponding positions of the insulation board. The diameter of the reserved holes for the insulation connector matches the diameter of the first rubber sleeve on the insulation connector. Step S7: Pass the insulation connector through the insulation connector pre-drilled hole on the insulation board, and use the tray to fit the insulation connector so that the tray is stuck at the bottom of the first rubber sleeve. The first rubber sleeve and the tray will hold the insulation board in place. Step S8: Before the inner leaf wall concrete has initially set, insert the insulation connector with the insulation board into the inner leaf wall concrete, with the lower end of the insulation connector passing through the inner leaf wall concrete and contacting the formwork. Step S81: Pass the embedded hanger through the pre-drilled hole on the insulation board, so that one end of the embedded hanger is inserted into the inner leaf wall concrete and the other end of the embedded hanger protrudes from the upper surface of the insulation board. The length of the protruding part is not greater than the thickness of the inner leaf wall. Step S9: Tie the reinforcing bars of the outer leaf wall on the insulation board, pour the outer leaf wall concrete, and remove the formwork after the outer leaf wall concrete and inner leaf wall concrete have reached their strength to obtain the double-sided prefabricated insulated composite shear wall panel. Step S10: Send the double-sided prefabricated insulated composite shear wall panel into the curing kiln for curing.

2. The production structure of the double-sided prefabricated insulated composite shear wall panel according to claim 1, characterized in that, A support platform is provided on the inner side of the side mold, and the support platform supports the bottom edge of the insulation board.

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