A novel manufacturing method for thin and light exterior wall panels

Abstract

The present invention is suitable for providing a novel method for manufacturing a thin and light external wall panel, which comprises the following steps: S1, establishing a parametric information model of the external wall panel; S2, generating a corresponding parametric model of the mold according to the external wall panel model; S3, making a 3D printing mold; S4, positioning the steel mesh; S5, positioning the embedded bolts; S6, spraying UHPC; S7, demolding, surface treatment. The PC external wall panel manufacturing method of the present invention is convenient and simple for workers to operate, eliminating the step of hoisting the steel structure support by construction workers, and directly hoisting the external wall panel. The wall panels produced by the spraying method can fit the mold completely, so as to easily realize any thin and light curved surface. The material is light, has strong shape plasticity, flexible size, good durability, shortened operation cycle, and easy construction and installation. The mold is produced by parametric design and 3D automated printing, so that there is no limit to the design of the wall panel style.

Description

Technical Field

[0001] The invention belongs to the field of construction, and in particular relates to a method for manufacturing a novel light and thin external wallboard. Background Art

[0002] In recent years, with the hot development of prefabricated buildings, PC exterior wall panels have been used more and more widely, and their simple concrete exterior is deeply loved by architects. However, as more and more projects begin to use PC exterior walls, their shortcomings are increasingly exposed:

[0003] 1. PC external wall panels need to be pre-buried with back bolts connected to the main structure, and the thickness is generally not less than 300mm. Therefore, the weight of each square meter of PC external wall is more than 400kg, and the weight of a single component is usually more than 5t, which often requires a larger tonnage tower crane, greatly increasing the cost of on-site construction;

[0004] 2. The excessive weight of the PC external wall panel makes its connection with the main structure more complicated, and its connection nodes cannot be adjusted three-dimensionally, which greatly reduces the installation efficiency of the external wall;

[0005] 3. The steel bars in the PC external wall panels cannot be bent at will, which greatly increases the difficulty of achieving various shapes of PC external walls and limits the architects' thinking;

[0006] 4. The production of PC external wall panels adopts the casting-vibration process. This production process exerts a great force on the formwork and requires extremely high rigidity of the formwork, which greatly increases the cost of the formwork. Summary of the invention

[0007] The purpose of the present invention is to provide a novel method for manufacturing a thin and light external wall panel, aiming to solve the problems of heavy weight, low installation efficiency and high requirement on template rigidity of PC external wall panels manufactured by casting-vibration process in the prior art.

[0008] The present invention is achieved by a novel method for manufacturing a thin and light exterior wallboard, which comprises the following steps:

[0009] S1. Making a 3D printing mold: According to the shape of the target external wall panel, a 3D printing mold is made, wherein the 3D printing mold has a cavity, the bottom of the cavity is an exposed surface layer, a middle reinforcement stiffening rib is arranged in the middle of the cavity, the bottom surface of the middle reinforcement stiffening rib is a distance away from the exposed surface layer, and stiffening ribs and a waterproof structure are arranged around the cavity;

[0010] S2. Steel mesh positioning: steel mesh is placed on the four sides and the middle of the cavity of the 3D printing mold. A single-layer steel mesh is configured on the middle reinforcement stiffening rib. The front end of the steel mesh is anchored into the exposed surface layer through an anchor joint. Double-layer steel mesh is configured on the left and right stiffening ribs respectively, and a waterproof structure is set. Single-layer steel mesh is configured on the upper and lower stiffening ribs respectively.

[0011] S3. Embedded bolt positioning: Place the embedded bolts at the upper left and upper right of the cavity. The length of the embedded bolt hole is the thickness of the target external wall panel.

[0012] S4, spraying UHPC: 1) first spray the bottom of the cavity to form the plate body of the external wall panel, 2) then spray the steel mesh on the four sides to form the stiffening ribs of the external wall panel, wherein when spraying the stiffening ribs on the left and right sides of the external wall panel, reserve the installation holes for the embedded bolts; 3) finally, spray the steel mesh in the middle to form the middle stiffening ribs of the external wall panel;

[0013] S5. Demolding and surface treatment: After the 3D printed UHPC is dry and reaches the expected strength, the external wall panels are demoulded and their surfaces are smoothed.

[0014] Furthermore, the thickness of the plate body, the upper and lower stiffening ribs and the middle stiffening ribs of the external wall panel are all 30 mm; the stiffening ribs on the left and right sides are structural members, and their thickness is 50 mm.

[0015] Furthermore, the 3D printing mold production includes the following steps:

[0016] Printing 3D Printing Mold:

[0017] According to the three-dimensional information of the target external wall panel, a parametric information model of the external wall panel is established: a parametric information model of the external wall panel is established using architectural three-dimensional design software (such as rhino, revit, etc.);

[0018] Generate the corresponding parametric information model of the 3D printing mold according to the external wall panel model: import the building 3D model file into the dedicated software to automatically generate the 3D model and printing path of the corresponding 3D printing mold;

[0019] Split the 3D printing mold model into several mold units in the software, and the size of each mold unit shall not exceed 500mmx500mm;

[0020] Print the split mold units separately;

[0021] Grind and polish each printed mold unit;

[0022] 3D printing mold assembly:

[0023] Each module unit is assembled in the factory to form a unit mold.

[0024] Furthermore, the plurality of mold units include four stiffening ribs located at the upper, lower, left and right sides, a plurality of middle reinforcement stiffening ribs located in the middle, and an exposed surface layer located at the bottom.

[0025] Furthermore, the 3D printing mold is a plastic mold, a steel mold or a wooden mold.

[0026] Furthermore, the steel mesh in the middle is arranged longitudinally at intervals of 600-800mm.

[0027] Furthermore, after the external wall panel is manufactured, the empty area on the back thereof is filled with thermal insulation material.

[0028] Compared with the prior art, the present invention has the following beneficial effects:

[0029] 1. The manufacturing method of the PC external wallboard of the present invention eliminates the step of steel bar binding, simplifies the production process of the PC external wallboard, reduces the design difficulty of the PC external wallboard, and improves the production efficiency of the PC external wallboard;

[0030] 2. The PC external wall panels produced by the injection method can fit the mold completely, so as to easily realize thin and curved surfaces of any shape;

[0031] 3. The injection production process does not require high rigidity of the mold and causes little damage to the mold, which can greatly reduce the production cost and loss of the mold;

[0032] 4. The weight of PC external wall panels produced by the spraying method is about 80-100 kg per square meter, which is 1 / 5 of the weight of traditional PC external wall panels. The transportation and installation costs are much lower than traditional PC wall panels.

[0033] 5. It eliminates the need for construction workers to hoist the steel structure support step, and can directly hoist the external wall panels. The PC external wall panels produced by the injection method have pre-buried bolts on the back, which can be simply hung with the main structure, which can greatly reduce the difficulty of installing the wall panels;

[0034] 6. According to preliminary estimates, due to the savings in transportation, installation and mold costs, the comprehensive cost of PC external wall panels produced by the injection molding method can be reduced by more than 10% compared with traditional PC external wall panels (the more complex the shape of the wall panels, the greater the cost reduction). BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 It is a flow chart of a method for manufacturing a novel thin and light exterior wallboard provided by an embodiment of the present invention;

[0036] Figure 2It is a structural schematic diagram of a 3D printing mold for making a new type of thin and light exterior wall panel provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0037] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0038] In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention; the terms "first", "second", and "third" are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance; in addition, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be directly connected, or indirectly connected through an intermediate medium, or it can be a connection between the two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0039] See also Figure 1 , shows a method for manufacturing a novel thin and light exterior wallboard provided by an embodiment of the present invention, comprising the following steps:

[0040] S1. Establish a parametric information model of the external wall panel according to the three-dimensional information of the target external wall panel: establish a parametric information model of the external wall panel using architectural three-dimensional design software (such as rhino, revit, etc.);

[0041] S2. Generate a parametric information model of a corresponding 3D printing mold according to the external wall panel model: import the building 3D model file into the dedicated software to automatically generate a 3D model and a printing path of the corresponding 3D printing mold;

[0042] S3. Making 3D printing mold:

[0043] 3D printing mold printing:

[0044] Split the 3D printing mold model into several mold units in the software, and the size of each mold unit shall not exceed 500mmx500mm;

[0045] Print the split mold units separately; specifically, the mold units include four upper, lower, left and right stiffening ribs 13 located on the periphery, a plurality of middle reinforcement stiffening ribs 12 located in the middle, and an exposed surface layer 11 located at the bottom;

[0046] Grind and polish each printed mold unit;

[0047] 3D printing mold assembly:

[0048] Each module unit is assembled in the factory to form a unit mold.

[0049] See also Figure 2 The 3D printing mold has a cavity 1, the bottom of the cavity 1 is an exposed surface layer 11, a middle reinforcement stiffening rib 12 is provided in the middle of the cavity 1, the bottom surface of the middle reinforcement stiffening rib 12 is a distance away from the exposed surface layer 11, and stiffening ribs 13 and a waterproof structure are provided around the cavity 1.

[0050] S4. Steel mesh positioning:

[0051] Steel meshes are placed on the four sides and the middle of the 3D printing mold cavity 1, and a single-layer steel mesh is configured on the middle reinforcement stiffening rib 12. The steel meshes are placed at intervals in the longitudinal direction with a spacing of 600-800mm; the front end of the steel mesh is anchored into the exposed surface layer 11 through an anchor joint, and double-layer steel meshes are respectively configured on the left and right stiffening ribs 13, and a waterproof structure is set, and single-layer steel meshes are respectively configured on the upper and lower stiffening ribs 13.

[0052] S5. Embedded bolt positioning:

[0053] The embedded bolts are placed at the upper left and upper right of the cavity 1, and the length of the embedded bolt holes is the thickness of the target external wall panel.

[0054] S6, Spray UHPC:

[0055] 1) First, spray the bottom of the cavity 1 to form the body of the external wall panel;

[0056] 2) Then, the steel mesh on the four sides is sprayed to form the stiffening ribs of the external wall panel. When spraying the stiffening ribs on the left and right sides of the external wall panel, the installation holes for the embedded bolts are reserved;

[0057] 3) Finally, spray the steel mesh in the middle to form the middle stiffening rib of the external wall panel;

[0058] Among them, the thickness of the plate body, the upper and lower side stiffening ribs and the middle stiffening ribs of the external wall panel are all 30mm; the left and right side stiffening ribs are structural components, and their thickness is 50mm.

[0059] S7, demoulding, surface treatment:

[0060] After the 3D-printed UHPC is dry and reaches the expected strength, the external wall panels are demoulded and their surfaces are smoothed, and the empty areas on the back of the external wall panels are filled with insulation materials.

[0061] It is easy to understand that the 3D printing mold of this embodiment can be a plastic mold, a steel mold or a wooden mold.

[0062] In summary, the PC external wallboard manufacturing method of this embodiment is adopted, and the construction operation steps of the workers are convenient and simple, eliminating the construction workers' hoisting steel structure support steps, and the external wallboard can be directly hoisted. The wallboard produced by the injection method can completely fit the mold, so as to easily realize any thin and light curved surface. The material is light, the shape is highly plastic, the size is flexible, the durability is good, the operation cycle is shortened, and the construction and installation are easy. The mold adopts parametric design and 3D automated printing production, so that the wallboard style design is unlimited.

[0063] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A novel method for manufacturing a thin and light exterior wallboard, characterized in that: The following steps are involved: S1. Making a 3D printing mold: According to the shape of the target external wall panel, a 3D printing mold is made, wherein the 3D printing mold has a cavity, the bottom of the cavity is an exposed surface layer, a middle reinforcement stiffening rib is arranged in the middle of the cavity, the bottom surface of the middle reinforcement stiffening rib is a distance away from the exposed surface layer, and stiffening ribs and a waterproof structure are arranged around the cavity; S2. Steel mesh positioning: steel mesh is placed on the four sides and the middle of the cavity of the 3D printing mold. A single-layer steel mesh is configured on the middle reinforcement stiffening rib. The front end of the steel mesh is anchored into the exposed surface layer through an anchor joint. Double-layer steel mesh is configured on the left and right stiffening ribs respectively, and a waterproof structure is set. Single-layer steel mesh is configured on the upper and lower stiffening ribs respectively. S3. Embedded bolt positioning: Place the embedded bolts at the upper left and upper right of the cavity. The length of the embedded bolt hole is the thickness of the target external wall panel. S4, spraying UHPC: 1) first spray the bottom of the cavity to form the plate body of the external wall panel, 2) then spray the steel mesh on the four sides to form the stiffening ribs of the external wall panel, wherein when spraying the stiffening ribs on the left and right sides of the external wall panel, reserve the installation holes for the embedded bolts; 3) finally, spray the steel mesh in the middle to form the middle stiffening ribs of the external wall panel; S5. Demolding and surface treatment: After the 3D printed UHPC is dry and reaches the expected strength, the external wall panels are demoulded and their surfaces are smoothed.

2. The manufacturing method according to claim 1, characterized in that The thickness of the plate body, upper and lower side stiffening ribs and middle stiffening ribs of the external wall panel are all 30mm; the left and right side stiffening ribs are structural components with a thickness of 50mm.

3. The manufacturing method according to claim 1, characterized in that: The 3D printing mold production includes the following steps: Printing 3D Printing Mold: According to the three-dimensional information of the target external wall panel, a parametric information model of the external wall panel is established using architectural three-dimensional design software; Generate a corresponding parametric information model of a 3D printing mold according to the parametric information model of the external wall panel: import the parametric information model file of the external wall panel into the dedicated software to automatically generate a three-dimensional model and a printing path of the corresponding 3D printing mold; Split the 3D printing mold model into several mold units in the software, and the size of each mold unit shall not exceed 500mmx500mm; Print the split mold units separately; Grind and polish each printed mold unit; 3D printing mold assembly: Each module unit is assembled in the factory to form a unit mold.

4. The manufacturing method according to claim 3, characterized in that: The plurality of mold units include four reinforcing ribs located at the upper, lower, left and right sides, a plurality of middle reinforcement reinforcing ribs located in the middle, and an exposed surface layer located at the bottom.

5. The manufacturing method according to claim 1, characterized in that: The 3D printing mold is a plastic mold, a steel mold or a wooden mold.

6. The manufacturing method according to claim 1, characterized in that: The steel mesh in the middle is arranged longitudinally at intervals of 600-800mm.

7. The manufacturing method according to claim 1, characterized in that: After the exterior wall panel is manufactured, the empty area on the back thereof is filled with thermal insulation material.

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