Prefabricated panel with mold and manufacturing method thereof

Abstract

This invention discloses a precast slab with a mold and its manufacturing method. The key technical point is that the precast slab includes a slab body and a mold, with the mold surrounding the slab body. The mold includes an outer wall, an inner hole wall, a connector, a nut, and an adjusting component. The outer wall surrounds the slab body, the inner hole wall is located inside the outer wall and fixedly connected to it via the connector, and the inner hole wall forms an adjusting hole. A nut is fixed inside the adjusting hole, and the adjusting component is screwed onto the nut. The head of the adjusting component extends out of the adjusting hole, and the screw end of the adjusting component has a notch for easy rotation. The manufacturing method includes inserting a functional layer into the mold, pouring mortar into the receiving space formed by the other end face of the functional layer and the mold until the upper end face of the mortar is coplanar with the end face of the mold; allowing it to stand until the mortar hardens, and then curing the mortar to obtain the precast slab with the mold. This precast slab has high production efficiency and is not easily damaged.

Description

Technical Field

[0001] The invention relates to the field of assembled floor slabs, and more particularly to a prefabricated slab with a mold and a manufacturing method thereof. Background Art

[0002] Prefabricated buildings refer to buildings that transfer a large amount of on-site work in traditional construction methods to factories, where building components and accessories are processed and manufactured, then transported to the construction site, and assembled and installed on site through reliable connection methods. Prefabricated buildings have developed rapidly in recent years due to their advantages such as standardized manufacturing, ease of large-scale production, and convenient construction. Prefabricated floor slabs, as part of prefabricated buildings, have also developed rapidly.

[0003] Existing prefabricated floors are usually assembled from several prefabricated panels. The prefabricated panels usually include a functional layer and a protective surface layer. The functional layer is a flexible layer used to provide thermal insulation or sound insulation to the prefabricated panel, and the protective surface layer is a rigid layer used to provide rigidity to the prefabricated panel. The production process of prefabricated panels is usually as follows: put thermal insulation and sound insulation materials into the mold and pour slurry. After the slurry reaches a certain strength, use a release agent to separate the mold from the material in the mold. The prefabricated panel is obtained after separation, and the mold is reused to make the next prefabricated panel.

[0004] However, waiting for the slurry to reach the strength that can be separated from the mold takes a lot of time, usually one day, resulting in a long production time for the prefabricated board and low production efficiency. In addition, the contact between the prefabricated board and the mold may be damaged during the separation process, resulting in the scrapping of the prefabricated board. Summary of the invention

[0005] In view of the shortcomings of the prior art, one of the purposes of the present invention is to provide a prefabricated panel with a mold, which has high production efficiency and is not easy to damage. Another purpose of the present invention is to provide a manufacturing method of a prefabricated panel with a mold, which can improve the production efficiency of the prefabricated panel and reduce the damage rate of the prefabricated panel during the manufacturing process.

[0006] To achieve the above-mentioned purpose, the present invention provides the following technical solution: comprising a plate body and a mold, wherein the mold is arranged around the plate body and is fixedly connected to the plate body.

[0007] As a further improvement of the present invention, the mold includes an outer enclosing wall, an inner hole wall, a connecting piece, a nut and a height adjusting piece. The outer enclosing wall is arranged around the plate body, the inner hole wall is located inside the outer enclosing wall and is fixedly connected to the outer hole through the connecting piece, the inner hole wall forms an adjustment hole, the nut is fixed in the adjustment hole, the height adjusting piece is screwed on the nut, one end of the height adjusting piece extends out of the adjustment hole and is used to contact the ground, and the other end of the height adjusting piece is provided with a recess for facilitating the rotation of the height adjusting piece.

[0008] With this arrangement, construction workers can insert a screwdriver into the recess to turn the height-adjusting piece. During rotation, the length of the height-adjusting piece extending out of the adjustment hole changes, thereby adjusting the height of the prefabricated panels from the ground to facilitate leveling of adjacent prefabricated panels, that is, the upper surfaces of the prefabricated panels are the same height.

[0009] As a further improvement of the present invention, the adjustment hole includes a large hole and a small hole coaxially arranged, the nut is embedded in the large hole, and the height adjustment member extends out of the adjustment hole from one end of the large hole.

[0010] Through such an arrangement, the step surface between the large hole and the small hole has a limiting effect on the nut, which can prevent the nut from sliding and affecting the height adjustment of the prefabricated plate by the height adjusting part. The large hole is located below the small hole, and the height adjusting part is threadedly connected to the nut in the large hole, so that the small hole can provide an accommodating space for the upper end of the height adjusting part, thereby increasing the height adjustment range of the prefabricated plate by the height adjusting part.

[0011] As a further improvement of the present invention, the connecting member, the inner hole wall, the nut and the height adjusting member are provided in plurality, and the inner hole wall, the nut and the height adjusting member are provided in one-to-one correspondence.

[0012] Through such an arrangement, each prefabricated panel is heightened through a plurality of height-adjusting members, so that the prefabricated panel can be placed more stably after height adjustment, and the height adjustment accuracy of each part of the prefabricated panel is higher.

[0013] As a further improvement of the present invention, the mold is provided with buckles for assembling a plurality of prefabricated panels together.

[0014] Through such an arrangement, each prefabricated panel can be overlapped by snap-fit ​​during construction, which facilitates the splicing of the prefabricated panels, helps to reduce the difficulty of adjusting the height of the prefabricated panels and improves construction efficiency.

[0015] As a further improvement of the present invention, the plate body includes a functional layer and a protective surface layer, the protective surface layer is located above the functional layer and fixedly connected to the functional layer, and a reinforcing rib is provided at the connection between the mold and the protective surface layer.

[0016] By this arrangement, the functional layer can be made of heat-insulating or sound-insulating materials, so that the prefabricated board has heat-insulating and sound-insulating properties, and the protective surface layer can provide sufficient rigidity. The arrangement of the reinforcing ribs can increase the strength of the mold and prevent the mold from tipping over and bending.

[0017] As a further improvement of the present invention, the plate body includes a functional layer and a protective surface layer, the protective surface layer is located above the functional layer and fixedly connected to the functional layer, and a support clamp is provided at the contact point between the mold and the functional layer, and the support clamp limits the functional layer from falling from one side of the mold.

[0018] Through such an arrangement, the supporting clamp can limit the functional layer and effectively prevent the functional layer from falling off.

[0019] As a further improvement of the present invention, the plate body includes a functional layer and a protective surface layer, the protective surface layer is located above the functional layer and fixedly connected to the functional layer, anti-cracking fibers are distributed in the protective surface layer and / or an anti-cracking layer is provided, and the anti-cracking layer is made of anti-cracking material.

[0020] By such arrangement, the anti-cracking fibers and / or the anti-cracking layer can improve the anti-cracking performance of the protective surface layer, so that the prefabricated board is not easy to crack.

[0021] To achieve the above object, the present invention provides the following technical solution: providing a mold, a functional layer and a mortar slurry, wherein the outer contour of the functional layer is adapted to the inner contour of the mold, and the method comprises the following steps:

[0022] S1: inserting the functional layer into the mold, and making one end surface of the functional layer coplanar with one end surface of the mold;

[0023] S2: pouring the mortar into the accommodation space enclosed by the other end surface of the functional layer and the mold until the upper end surface of the mortar is coplanar with the end surface of the mold;

[0024] S3: standing still until the mortar slurry hardens, and curing the mortar slurry to obtain a prefabricated panel with a mold.

[0025] As a further improvement of the present invention, a crack-resistant mesh cloth or wire mesh or steel mesh is provided, and step S2 also includes laying the crack-resistant mesh cloth or wire mesh or steel mesh into the accommodation space before pouring the mortar slurry into the accommodation space.

[0026] By such arrangement, the anti-cracking mesh cloth or wire mesh or steel mesh is laid, so that the manufactured prefabricated panels have anti-cracking properties.

[0027] As a further improvement of the present invention, anti-cracking fibers are mixed into the mortar slurry.

[0028] By means of such arrangement, the manufactured prefabricated panel has crack resistance.

[0029] As a further improvement of the present invention, the mold includes an outer enclosing wall, an inner hole wall, a connecting piece, a nut and a height adjusting piece. The inner hole wall is located inside the outer enclosing wall and is fixedly connected to the outer wall through the connecting piece. The inner hole wall forms an adjustment hole. The nut is fixed in the adjustment hole. The height adjusting piece is screwed on the nut. The head of the height adjusting piece extends out of the adjustment hole. The head of the height adjusting piece is used to contact the ground. The end of the screw of the height adjusting piece is provided with a notch for facilitating the rotation of the height adjusting piece.

[0030] Through such an arrangement, the manufactured prefabricated panels have a height adjustment function, which makes it convenient for construction workers to level the prefabricated panels.

[0031] Beneficial effects of the present invention: the prefabricated board is integrated with the board body through the mold, the mold is a consumable, and is used together with the board body to form the prefabricated board, so the mold does not need to be separated from the board body when making the prefabricated board, the processing efficiency of the prefabricated board is high, and the mold has a protective effect on the board body, which can prevent the board body from being damaged by collision, so the prefabricated board is less likely to be damaged. The manufacturing method does not need to separate the mold from the board body, the processing efficiency is higher, and at the same time, it avoids the contact between the board body and the mold from being damaged when the mold is separated from the board body, thereby improving the yield rate of the prefabricated board. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 is a schematic diagram of the three-dimensional structure of Example 1;

[0033] Figure 2 is a cross-sectional view of Example 1;

[0034] Figure 3 is a cross-sectional view of Example 2;

[0035] Figure 4 is a schematic diagram of the three-dimensional structure of Example 3;

[0036] Figure 5 is a cross-sectional view of Example 3;

[0037] Figure 6 for Figure 5 The enlarged view of point A in the middle;

[0038] Figure 7 This is a flow chart of Example 4.

[0039] Figure numerals: 1, plate body; 11, functional layer; 12, protective surface layer; 121, anti-crack fiber; 122, anti-crack layer; 2, mold; 21, outer wall; 211, reinforcing rib; 212, supporting clamp; 22, inner hole wall; 23, connecting piece; 24, nut; 25, height adjustment piece; 251, notch; 26, adjustment hole; 27, buckle. DETAILED DESCRIPTION

[0040] The present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. The same parts are represented by the same reference numerals. It should be noted that the words "front", "rear", "left", "right", "upper" and "lower" used in the following description refer to directions in the accompanying drawings, and the words "bottom surface" and "top surface", "inner" and "outer" refer to directions toward or away from the geometric center of a specific component, respectively.

[0041] Embodiment 1:

[0042] Reference Figure 1 , Figure 2 As shown, a prefabricated panel with a mold in this embodiment includes a panel body 1 and a mold 2. The mold 2 is arranged around the panel body 1 and is fixedly connected to the panel body 1. The panel body 1 can be set as a polygon. The panel body 1 in this embodiment is a rectangular parallelepiped, and the mold 2 is arranged on the four sides of the rectangular panel body 1.

[0043] Reference Figure 1 , Figure 2 As shown, the mold 2 is provided with buckles 27 for assembling a plurality of prefabricated panels together. For example, a clamping block and a clamping slot may be provided on the side wall of the mold 2, and the assembly between adjacent prefabricated panels can be achieved by clamping the clamping block into the clamping slot.

[0044] Reference Figure 1 , Figure 2 As shown, the plate body 1 includes a functional layer 11 and a protective surface layer 12, the protective surface layer 12 is located above the functional layer 11 and is fixedly connected to the functional layer 11, and the functional layer 11 is made of a thermal insulation and sound insulation composite material, or a thermal insulation and sound insulation material, or a thermal insulation material, or a sound insulation material. The thermal insulation and sound insulation material is a single material that has both thermal insulation and sound insulation effects, the thermal insulation material is a material with a thermal insulation function, and the sound insulation material is a material with a sound insulation function. The functional layer 11 can also be configured to include a thermal insulation layer and a sound insulation layer connected to each other, the thermal insulation layer is made of a thermal insulation material, and the sound insulation layer is made of a sound insulation material. In this embodiment, the protective surface layer 12 is made of a thermal insulation and sound insulation material.

[0045] Reference Figure 2As shown, a reinforcing rib 211 is provided at the connection between the mold 2 and the protective surface layer 12. The protective surface layer 12 is one of anti-crack mortar, plaster mortar, cement mortar, gypsum mortar, and sandless gypsum mortar. Anti-crack fibers 121 and / or an anti-crack layer 122 are distributed in the protective surface layer 12. In this embodiment, anti-crack fibers 121 are distributed in the protective surface layer 12 and an anti-crack layer 122 is provided at the same time. The anti-crack layer 122 is located in the middle of the height direction of the protective surface layer 12 or in the upper or lower position of the middle. The anti-crack layer 122 is made of an anti-crack material, such as an anti-crack mesh cloth material, a steel mesh, or a wire mesh.

[0046] Embodiment 2:

[0047] Reference Figure 3 As shown, the difference between this embodiment and embodiment 1 is that a support clamp 212 is provided at the contact point between the mold 2 and the functional layer 11. The support clamp 212 is configured as a triangular plate structure. One end face of the support clamp 212 is at the same height as the lower surface of the mold 2, and the other end face is connected to the inner side surface of the mold 2. The support clamp 212 is used to clamp the functional layer 11 to prevent the functional layer 11 from falling from one side of the mold 2.

[0048] Embodiment 3:

[0049] Reference Figure 4 , Figure 5 , Figure 6 As shown, the difference between this embodiment and embodiment 1 is that the mold 2 includes an outer wall 21, an inner hole wall 22, a connecting piece 23, a nut 24 and a height adjustment piece 25. The outer wall 21 is arranged around the plate body 1. The connecting piece 23, the inner hole wall 22, the nut 24 and the height adjustment piece 25 are all provided in plurality, and the inner hole wall 22, the nut 24 and the height adjustment piece 25 are provided in a one-to-one correspondence. The inner hole wall 22 is located inside the outer wall 21 and is fixedly connected to the outer wall 21 through the connecting piece 23. The connecting piece 23 can be a plate body 1 or a column. The connecting piece 23 can be provided in plurality. The connecting piece 23 connects the outer wall 21 and the inner hole wall 22 respectively, and the connecting piece 23, the outer wall 21 and the inner hole wall 22 are integrally formed.

[0050] Reference Figure 5 , Figure 6As shown, the inner hole wall 22 encloses an adjustment hole 26, and the adjustment hole 26 includes a large hole and a small hole arranged coaxially. The nut 24 is embedded in the large hole, and the height adjustment member 25 is screwed on the nut 24. One end of the height adjustment member 25 extends out of the adjustment hole 26 from the large hole and is used to contact the ground. A contact member is fixed at the contact point between the adjustment member and the ground, and the contact member is used to improve the contact stability between the adjustment member and the ground. For example, the contact member is set in a disc shape to increase the contact area with the ground. The other end of the height adjustment member 25 is located in the small hole, and is provided with a notch 251 for facilitating the rotation of the height adjustment member 25. The notch 251 is used to cooperate with a screwdriver to rotate the height adjustment member 25, and can be set to a straight line, a cross, a star, or an inner polygon, etc.

[0051] During construction, the construction workers place the end of the height adjusting member 25 of the prefabricated board extending out of the adjusting hole 26 on the ground downward. The construction workers rotate the height adjusting member 25 with a screwdriver to adjust the length of the height adjusting member 25 extending out of the adjusting hole 26, thereby adjusting the height of each part of the prefabricated board, thereby achieving the height adjustment of the prefabricated board.

[0052] Embodiment 4:

[0053] Reference Figure 7 As shown, a method for manufacturing a prefabricated panel with a mold in this embodiment provides mortar slurry, a functional layer 11 as described in Example 1, and a mold 2 as described in Example 1, Example 2, or Example 3, and also provides an anti-cracking mesh cloth or wire mesh or steel mesh. The outer contour of the functional layer 11 is equal to or slightly smaller than the inner contour of the mold 2.

[0054] The method comprises the following steps:

[0055] S1: insert the functional layer 11 into the mold 2 and make the lower end surface of the functional layer 11 coplanar with the lower end surface of the mold 2 .

[0056] S2: Lay the anti-cracking mesh cloth or wire mesh or steel mesh in the accommodation space enclosed by the upper end surface of the functional layer 11 and the inner side surface of the mold 2, and pour the mortar slurry into the accommodation space until the upper end surface of the mortar slurry is coplanar with the upper end surface of the mold 2. The mortar slurry is one of anti-cracking mortar, plastering mortar, cement mortar, gypsum mortar, sandless gypsum mortar, and concrete. The mortar slurry is mixed with anti-cracking fibers 121.

[0057] S3: standing still until the mortar slurry hardens, and curing the mortar slurry to obtain a prefabricated board with a mold 2.

[0058] The above are only preferred embodiments of the present invention. The protection scope of the present invention is not limited to the above embodiments. All technical solutions under the concept of the present invention belong to the protection scope of the present invention. It should be pointed out that for ordinary technicians in this technical field, some improvements and modifications without departing from the principle of the present invention should also be regarded as the protection scope of the present invention.

Claims

1. A prefabricated panel with a mold, characterized in that: The invention comprises a plate body (1) and a mold (2), wherein the mold (2) is arranged around the plate body (1) and is fixedly connected to the plate body (1), wherein the plate body (1) comprises a functional layer (11) and a protective surface layer (12), wherein the protective surface layer (12) is located above the functional layer (11) and is fixedly connected to the functional layer (11), and wherein the mold (2) comprises an outer wall (21), an inner hole wall (22), a connecting piece (23), a nut (24) and a height adjusting piece (25), wherein the outer wall (21) is arranged around the plate body (1), and the inner hole wall (22) is located inside the outer wall (21) and is connected to the outer wall (21) by a screw thread. The connecting member (23) is fixedly connected, the inner hole wall (22) encloses an adjusting hole (26), the nut (24) is fixed in the adjusting hole (26), the height adjusting member (25) is screwed on the nut (24), one end of the height adjusting member (25) extends out of the adjusting hole (26) and is used to contact the ground, the other end of the height adjusting member (25) is provided with a notch (251) for facilitating the rotation of the height adjusting member (25), the adjusting hole (26) includes a large hole and a small hole coaxially arranged, the nut (24) is embedded in the large hole, and the height adjusting member (25) extends out of the adjusting hole (26) from one end of the large hole, The method for manufacturing the prefabricated board comprises: providing a mold (2), a functional layer (11) and a mortar slurry, wherein the outer contour of the functional layer (11) is adapted to the inner contour of the mold (2), and the method comprises the following steps: S1: inserting the functional layer (11) into the mold (2), and making one end surface of the functional layer (11) coplanar with one end surface of the mold (2); S2: pouring the mortar into the accommodation space enclosed by the other end surface of the functional layer (11) and the mold (2), until the upper end surface of the mortar is coplanar with the end surface of the mold (2); S3: leaving the mortar to stand until the mortar is hardened, and curing the mortar to obtain a prefabricated board with a mold (2).

2. A prefabricated panel with a mold according to claim 1, characterized in that: The connecting member (23), the inner hole wall (22), the nut (24) and the height adjusting member (25) are all provided in plurality, and the inner hole wall (22), the nut (24) and the height adjusting member (25) are provided in a one-to-one correspondence.

3. A prefabricated panel with a mold according to claim 1, characterized in that: The mold (2) is provided with buckles (27) for facilitating mutual assembly of a plurality of prefabricated panels.

4. A prefabricated panel with a mold according to claim 1, characterized in that: A reinforcing rib (211) is provided at the connection between the mold (2) and the protective surface layer (12).

5. The prefabricated panel with a mold according to claim 1, characterized in that: A support clamp (212) is provided at the contact point between the mold (2) and the functional layer (11), and the support clamp (212) limits the functional layer (11) from falling from one side of the mold (2).

6. A prefabricated panel with a mold according to claim 1, characterized in that: The protective surface layer (12) is provided with anti-cracking fibers (121) and / or an anti-cracking layer (122), and the anti-cracking layer (122) is made of an anti-cracking material.

7. The prefabricated panel with a mold according to claim 1, characterized in that: Providing anti-cracking mesh cloth or wire mesh or steel mesh, step S2 also includes laying the anti-cracking mesh cloth or wire mesh or steel mesh into the accommodation space before pouring the mortar slurry into the accommodation space.

8. The prefabricated panel with a mold according to claim 1, characterized in that: Anti-cracking fibers (121) are mixed in the mortar slurry.

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