Modular Energy-Saving Prefabricated Exterior Wall Panels and Their Preparation Method

Abstract

This invention relates to a modular energy-saving prefabricated exterior wall panel, belonging to the field of prefabricated building technology. Its main objective is to provide a durable modular energy-saving prefabricated exterior wall panel. The modular energy-saving prefabricated exterior wall panel includes: a concrete shell panel comprising a first panel, a second panel, a top panel, and a bottom panel. The first and second panels face each other, forming a filling space between them. The top panel is located at the top of the filling space, connecting the top of the first and second panels. The bottom panel is located at the bottom of the filling space, connecting the bottom of the first and second panels. A functional core layer fills the filling space, with its outer ring exposed on both sides of the filling space. The modular energy-saving prefabricated exterior wall panel eliminates the thermal bridges in the shell panel vertically on both sides, maintaining the continuity of the vertical insulation layer and significantly improving the energy-saving insulation effect. Compared to ordinary sandwich wall panels, it reduces thermal bridges in the panel joints by more than 60%.

Description

Technical Field

[0001] This invention relates to the field of prefabricated building technology, and in particular to a modular energy-saving prefabricated exterior wall panel and its preparation method. Background Technology

[0002] Traditional prefabricated building technology typically uses precast concrete exterior wall panels as cladding, employing a fully reinforced concrete structure, resulting in a relatively heavy and bulky structure. This situation has remained largely unchanged for decades. Furthermore, additional insulation and fireproofing layers are required on the outside of the precast concrete exterior wall panels, leading to higher construction costs.

[0003] Existing precast concrete exterior wall panels with reinforced concrete structures are no longer adequate to meet the needs of current prefabricated building construction in terms of integrated functions such as thermal insulation, heat insulation, fireproofing, waterproofing, durability, and decoration. There is an urgent need to develop new types of exterior wall panels that are lightweight, have large panels, are efficient to manufacture, easy to install, and combine multiple functions of the exterior wall cladding, with good durability and an aesthetically pleasing appearance. Summary of the Invention

[0004] In view of this, the present invention provides a modular energy-saving prefabricated exterior wall panel, the main purpose of which is to provide a durable modular energy-saving prefabricated exterior wall panel.

[0005] To achieve the above objectives, the embodiments of the present invention mainly provide the following technical solutions:

[0006] On one hand, embodiments of the present invention provide a combined energy-saving prefabricated exterior wall panel, comprising:

[0007] A concrete shell plate includes a first panel, a second panel, a top plate, and a bottom plate. The first panel and the second panel are opposite each other, and a filling space is formed between the first panel and the second panel. The top plate is located at the top of the filling space and connects the top of the first panel and the top of the second panel. The bottom plate is located at the bottom of the filling space and connects the bottom of the first panel and the bottom of the second panel.

[0008] A functional core layer is filled in the filling space, and the outer ring of the functional core layer is exposed on both sides of the filling space.

[0009] The objectives of the embodiments of the present invention and the technical problems to be solved therefrom can be further achieved by the following technical measures.

[0010] Optionally, in the aforementioned combined energy-saving prefabricated exterior wall panel, the functional core layer includes: a three-dimensional steel wire mesh frame and a core material, wherein the core material is filled in the three-dimensional steel wire mesh frame, and the three-dimensional steel wire mesh frame includes a first side and a second side, wherein the steel wires of the first side are inserted into the first panel, and the steel wires of the second side are inserted into the second panel.

[0011] Optionally, in the aforementioned combined energy-saving prefabricated exterior wall panel, the three-dimensional steel wire mesh frame includes a first transverse steel bar, a second transverse steel bar, and intersecting steel bars. The first transverse steel bar is parallel to the second transverse steel bar, and the intersecting steel bars are welded to the first transverse steel bar and the second transverse steel bar. The first intersecting branch end of the intersecting steel bar extends outward from the first transverse steel bar into the first panel, and the second intersecting branch end of the intersecting steel bar extends outward from the second transverse steel bar into the second panel.

[0012] Optionally, in the aforementioned combined energy-saving prefabricated exterior wall panel, the first transverse steel bar and the second transverse steel bar are located between the first panel and the second panel.

[0013] Optionally, in the aforementioned combined energy-saving prefabricated exterior wall panel, the first transverse steel bar is located inside the first panel, and the second transverse steel bar is located inside the second panel.

[0014] Optionally, in the aforementioned combined energy-saving prefabricated exterior wall panel, the shell panel is provided with a window, and the inner ring of the functional core layer is exposed through the window.

[0015] Optionally, in the aforementioned combined energy-saving prefabricated exterior wall panel, a wooden block for window installation is pre-embedded between the first panel and the second panel at the window location.

[0016] Optionally, in the aforementioned combined energy-saving prefabricated exterior wall panel, the thickness dimension of the filling space from the inner ring to the outer ring direction between the first panel and the second panel gradually increases and then decreases.

[0017] Optionally, in the aforementioned combined energy-saving prefabricated exterior wall panel, the functional core layer is at least one of a thermal insulation layer, a fireproof layer, and a sound insulation layer.

[0018] On the other hand, embodiments of the present invention provide a method for preparing the above-mentioned combined energy-saving prefabricated exterior wall panel, comprising:

[0019] Pour the bottom layer of concrete into the wall panel mold to form the first panel;

[0020] A functional core layer is placed on the bottom concrete, with the two sides of the functional core layer abutting against the two sides of the wall panel mold. A first pouring space is reserved at the top of the functional core layer and the top of the wall panel mold, and a second pouring space is reserved at the bottom of the functional core layer and the bottom of the wall panel mold.

[0021] Top layer concrete is poured into the wall panel mold to form the top plate in the first pouring space, the bottom layer in the second pouring space, and the second panel is formed on the top plate, the functional core layer, and the bottom layer.

[0022] By means of the above technical solution, the combined energy-saving prefabricated exterior wall panel provided by the present invention has at least the following advantages:

[0023] In the technical solution provided by this invention, the functional core layer fills the space between the first panel and the second panel of the shell panel, giving the combined energy-saving prefabricated exterior wall panel additional functional attributes. Simultaneously, the outer ring of the functional core layer is exposed on both sides of the filling space, eliminating the thermal bridges in the shell panel on both sides of the combined energy-saving prefabricated exterior wall panel, maintaining the continuity of the vertical insulation layer, significantly improving the energy-saving insulation effect, and reducing thermal bridges in the panel joints by more than 60% compared to ordinary sandwich wall panels.

[0024] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the embodiments of the present invention and to implement them in accordance with the contents of the specification, the preferred embodiments of the present invention are described in detail below with reference to the accompanying drawings. Attached Figure Description

[0025] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings:

[0026] Figure 1 This is an axial side view of a combined energy-saving prefabricated exterior wall panel provided by an embodiment of the present invention;

[0027] Figure 2 This is a cross-sectional structural schematic diagram of a combined energy-saving prefabricated exterior wall panel provided by an embodiment of the present invention;

[0028] Figure 3 This is a schematic diagram of the cross-sectional structure of a combined energy-saving prefabricated exterior wall panel provided in an embodiment of the present invention;

[0029] Figure 4 This is a schematic diagram of the cross-sectional structure of another combined energy-saving prefabricated exterior wall panel provided by an embodiment of the present invention;

[0030] Figure 5 This is a schematic diagram of a three-dimensional steel wire mesh structure for a combined energy-saving prefabricated exterior wall panel provided by an embodiment of the present invention;

[0031] Figure 6 This is a schematic diagram of the process steps for preparing a combined energy-saving prefabricated exterior wall panel according to an embodiment of the present invention;

[0032] Figure 7 This is a cross-sectional structural diagram of the connecting part of a combined energy-saving prefabricated exterior wall panel provided in an embodiment of the present invention. Detailed Implementation

[0033] To further illustrate the technical means and effects adopted by the present invention to achieve the intended objectives of the embodiments, the following, in conjunction with the accompanying drawings and preferred embodiments, details the specific implementation methods, structures, features, and effects of the combined energy-saving prefabricated exterior wall panels proposed according to the embodiments of the present invention. In the following description, different "embodiments" or "embodiments" do not necessarily refer to the same embodiment. Furthermore, specific features, structures, or characteristics in one or more embodiments can be combined in any suitable form.

[0034] Figures 1 to 5 For an embodiment of the combined energy-saving prefabricated exterior wall panel provided by the present invention, please refer to [link / reference]. Figures 1 to 5 An embodiment of the present invention provides a combined energy-saving prefabricated exterior wall panel, comprising:

[0035] The concrete shell plate 10 includes a first panel 11, a second panel 12, a top plate 13, and a bottom plate 14. The first panel 11 and the second panel 12 are opposite each other, and a filling space is formed between the first panel 11 and the second panel 12. The top plate 13 is located at the top of the filling space and connects the top of the first panel 11 and the top of the second panel 12. The bottom plate 14 is located at the bottom of the filling space and connects the bottom of the first panel 11 and the bottom of the second panel 12.

[0036] The functional core layer 20 is filled in the filling space, and the outer ring of the functional core layer 20 is exposed from both sides of the filling space.

[0037] In the technical solution provided by this invention, the functional core layer 20 fills the space between the first panel 11 and the second panel 12 of the shell panel 10, giving the combined energy-saving prefabricated exterior wall panel additional functional attributes. Simultaneously, the outer ring of the functional core layer 20 is exposed on both sides of the filling space, eliminating the thermal bridges in the shell panel 10 vertically on both sides of the combined energy-saving prefabricated exterior wall panel, maintaining the continuity of the vertical insulation layer of the wall panel, significantly improving the energy-saving insulation effect, and reducing thermal bridges in the panel joints by more than 60% compared to ordinary sandwich wall panels.

[0038] The first panel 11 and the second panel 12 of the concrete shell panel 10 can each be an integral panel to meet the needs of using a whole wall panel. The functional core layers 20 on both sides of the concrete shell panel 10 are exposed. The functional core layer 20 is at least one of the following: thermal insulation layer, fireproof layer, and sound insulation layer. Different core layers are selected according to different needs. Of course, the function of the core layer is not limited to one type, and it can also be a combination of two or more types.

[0039] In order to securely clamp the functional core layer 20 between the first panel 11 and the second panel 12, the thickness of the filling space from the first side to the second side of the concrete shell plate 10 gradually increases and then decreases.

[0040] The first panel 11 and the second panel 12 of the concrete shell plate 10 can each serve as window panels. The shell plate 10 has windows, the filling space is annular, and the functional core layer 20 is annular, with the inner ring of the functional core layer 20 exposed through the windows. The exposed functional core layer 20 of the concrete shell plate 10 can be understood as a thermal break between the first panel 11 and the second panel 12 at the window location, thereby reducing heat conduction between the first panel 11 and the second panel 12 of the shell plate 10.

[0041] In specific implementation, at the window location, a wooden block 214 for window installation is pre-embedded between the first panel 11 and the second panel 12. Before the modular energy-saving prefabricated exterior wall panel is transported to the construction site, the window can be pre-installed in the pre-embedded wooden block 214. That is, during the construction and assembly process, the modular energy-saving prefabricated exterior wall panel with the window installed can be directly assembled into the main body of the building without the need for additional window installation procedures, thus improving the construction time of the building.

[0042] In order to securely clamp the functional core layer 20 between the first panel 11 and the second panel 12, the thickness of the filling space from the inner ring to the outer ring of the filling space between the first panel 11 and the second panel 12 gradually increases and then decreases.

[0043] In embodiments of the present invention, on the one hand, by configuring the thickness variation between the first panel 11 and the second panel 12, the functional core layer 20 is stably set within the filling space. On the other hand, in order to maintain high strength of the concrete-made shell panel 10, or to reduce the thickness of the first panel 11 and the second panel 12 to meet the needs of ultra-thin combined energy-saving prefabricated exterior wall panels, in some embodiments of the present invention, the functional core layer 20 includes: a three-dimensional steel wire mesh frame 21 and a core material 22. The core material 22 is filled in the three-dimensional steel wire mesh frame 21. The three-dimensional steel wire mesh frame 21 includes a first surface and a second surface, with the first surface and the second surface facing each other. The steel wires of the first surface are inserted into the first panel 11, and the steel wires of the second surface are inserted into the second panel 12. The modular energy-saving prefabricated exterior wall panel integrates a three-dimensional steel wire mesh structure 21 with a core material 22, and double-sided cast high-performance concrete as the protective layer structure (first panel 11, second panel 12). Compared with existing sandwich insulation wall panels, it offers higher cost-effectiveness, saving approximately 150-200 yuan per square meter. Furthermore, this wall panel series is suitable for all types of buildings in seismic fortification zones ranging from 6 to 9 degrees, covering all types of residential, public, and industrial buildings from low-rise and multi-story to high-rise and super high-rise. The core material 22 can be expandable polystyrene board, extruded polystyrene insulation board, or polyurethane material board, depending on different functional requirements.

[0044] In specific implementation, the three-dimensional wire mesh frame 21 structure can be a diagonally inserted combination structure. The three-dimensional wire mesh frame 21 includes a first transverse steel bar 211, a second transverse steel bar 212, and intersecting steel bars 213. The first transverse steel bar 211 and the second transverse steel bar 212 are parallel. The intersecting steel bars 213 are welded to the first transverse steel bar 211 and the second transverse steel bar 212. The first intersecting branch end of the intersecting steel bar 213 extends outward from the first transverse steel bar 211 into the first panel 11, and the second intersecting branch end of the intersecting steel bar 213 extends outward from the second transverse steel bar 212 into the second panel 12. The intersecting steel bars 213 can be mutually perpendicular. The first steel bar of the intersecting steel bar 213 is welded to the first transverse steel bar 211 and the second transverse steel bar 212 at a 45° angle, and the second steel bar of the intersecting steel bar 213 is welded to the first transverse steel bar 211 and the second transverse steel bar 212 at a -45° angle. It is easy to understand that the intersection angle of the intersecting steel bars 213 can be adjusted to different angles as needed. By employing cross-reinforcing bars 213, the first panel 11, core material 22, and second panel 12 are organically integrated, resulting in a compact structure and high cost-effectiveness, saving approximately 150-200 yuan per square meter. Furthermore, this wall panel series is suitable for all types of buildings in seismic fortification zones ranging from 6 to 9 degrees, covering all types of residential, public, and industrial buildings from low-rise and multi-story to high-rise and super high-rise.

[0045] Furthermore, the first transverse reinforcing bar 211 and the second transverse reinforcing bar 212 can be positioned at different locations. To improve the stability of the core material 22, the first transverse reinforcing bar 211 and the second transverse reinforcing bar 212 are located between the first panel 11 and the second panel 12, and the first transverse reinforcing bar 211 and the second transverse reinforcing bar 212 pass through the core material 22. To improve the stability of the shell plate 10, the first transverse reinforcing bar 211 is located inside the first panel 11, and the second transverse reinforcing bar 212 is located inside the second panel 12. Of course, the number of transverse reinforcing bars can also be greater. For example, three parallel reinforcing bars can be configured, located in the first panel 11, the core material 22, and the second panel 12 respectively, with the intersecting reinforcing bar 213 welded to the three reinforcing bars.

[0046] Based on the above-described embodiments of the combined energy-saving prefabricated exterior wall panels, Figure 6 For an embodiment of the preparation method of the combined energy-saving prefabricated exterior wall panel provided by the present invention, please refer to [link / reference]. Figure 6 An embodiment of the present invention provides a method for preparing a combined energy-saving prefabricated exterior wall panel, comprising:

[0047] A10. Pour the bottom layer 14 concrete into the wall panel mold to form the first panel 11;

[0048] In some embodiments, the finishing layer 30 may be poured into the wall panel mold before A10.

[0049] A20 places a functional core layer 20 on the bottom layer 14 concrete. The two sides of the functional core layer 20 abut against the two sides of the wall panel mold. A first pouring space is reserved at the top of the functional core layer 20 and the top of the wall panel mold. A second pouring space is reserved at the bottom of the functional core layer 20 and the bottom of the wall panel mold.

[0050] The functional core layer 20 may include a three-dimensional steel wire mesh frame 21 and a core material 22, wherein the core material 22 is filled in the three-dimensional steel wire mesh frame 21, and the steel wires on the first side of the three-dimensional steel wire mesh frame 21 are inserted into the first panel 11.

[0051] A3. Pour top layer concrete into the wall panel mold to form the top plate 13 in the first pouring space and the bottom layer 14 in the second pouring space. Form the second panel 12 on the top plate 13, the functional core layer 20, and the bottom layer 14.

[0052] The steel wire on the second side is inserted into the second panel 12.

[0053] In the technical solution provided by this invention, the functional core layer 20 fills the space between the first panel 11 and the second panel 12 of the shell panel 10, giving the combined energy-saving prefabricated exterior wall panel additional functional attributes. Simultaneously, the outer ring of the functional core layer 20 is exposed on both sides of the filling space, eliminating the thermal bridges in the shell panel 10 vertically on both sides of the combined energy-saving prefabricated exterior wall panel, maintaining the continuity of the vertical insulation layer of the wall panel, significantly improving the energy-saving insulation effect, and reducing thermal bridges in the panel joints by more than 60% compared to ordinary sandwich wall panels.

[0054] During assembly, such as Figure 7 As shown, after the adjacent combined energy-saving prefabricated exterior wall panels are horizontally joined, fireproof elastic materials, waterstop strips, thermal insulation strips, sealant and other sealing, waterproofing and thermal insulation measures can be installed at the side seams of the shell panel 10.

[0055] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0056] It is understood that the relevant features in the above-described devices can be referenced interchangeably. Furthermore, the terms "first," "second," etc., in the above embodiments are used to distinguish between embodiments and do not represent the superiority or inferiority of any particular embodiment.

[0057] Numerous specific details are set forth in the specification provided herein. However, it will be understood that embodiments of the invention may be practiced without these specific details. In some instances, well-known structures and techniques have not been shown in detail so as not to obscure the understanding of this specification.

[0058] Similarly, it should be understood that, in order to simplify this disclosure and aid in understanding one or more of the various aspects of the invention, features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof in the above description of exemplary embodiments of the invention. However, this disclosed apparatus should not be construed as reflecting an intention that the claimed invention requires more features than expressly recited in each claim. Rather, as reflected in the following claims, inventive aspects lie in fewer than all features of a single foregoing disclosed embodiment. Therefore, the claims following the detailed description are hereby expressly incorporated into this detailed description, wherein each claim itself is a separate embodiment of the invention.

[0059] Those skilled in the art will understand that the components in the apparatus of the embodiments can be adaptively changed and disposed in one or more apparatuses different from that embodiment. Components in the embodiments can be combined into a single component, and furthermore, they can be divided into multiple sub-components. Except that at least some of such features are mutually exclusive, any combination can be employed to combine all features disclosed in this specification (including the accompanying claims, abstract, and drawings) and all components of any apparatus so disclosed. Unless expressly stated otherwise, each feature disclosed in this specification (including the accompanying claims, abstract, and drawings) may be replaced by an alternative feature serving the same, equivalent, or similar purpose.

[0060] Furthermore, those skilled in the art will understand that although some embodiments described herein include certain features included in other embodiments but not others, combinations of features from different embodiments are intended to be within the scope of the invention and form different embodiments. For example, in the following claims, any of the claimed embodiments can be used in any combination. Various component embodiments of the invention can be implemented in hardware or in combinations thereof.

[0061] It should be noted that the above embodiments are illustrative of the invention and not restrictive, and that those skilled in the art can devise alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses should not be construed as limiting the claims. The word "comprising" does not exclude the presence of parts or components not listed in a claim. The word "a" or "an" preceding a part or component does not exclude the presence of a plurality of such parts or components. The invention can be implemented by means of a device comprising a plurality of different parts. In claims listing a plurality of parts, such parts may be embodied by the same item of part. The use of the words first, second, and third, etc., does not indicate any order. These words can be interpreted as names.

[0062] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A modular energy-saving prefabricated exterior wall panel, characterized in that, include: A concrete shell plate includes a first panel, a second panel, a top plate, and a bottom plate. The first panel and the second panel are opposite each other, and a filling space is formed between the first panel and the second panel. The top plate is located at the top of the filling space and connects the top of the first panel and the top of the second panel. The bottom plate is located at the bottom of the filling space and connects the bottom of the first panel and the bottom of the second panel. A functional core layer is filled in the filling space, and the outer ring of the functional core layer is exposed from both sides of the filling space; From the first side to the second side of the concrete shell plate, the thickness of the filling space gradually increases and then decreases again. The functional core layer includes a three-dimensional steel wire mesh frame and a core material. The core material fills the three-dimensional steel wire mesh frame, which includes a first surface and a second surface. The steel wires on the first surface are inserted into the first panel, and the steel wires on the second surface are inserted into the second panel. The three-dimensional steel wire mesh frame includes a first transverse steel bar, a second transverse steel bar, and intersecting steel bars. The first transverse steel bar and the second transverse steel bar are parallel. The intersecting steel bars are welded to the first transverse steel bar and the second transverse steel bar. The first intersecting branch of the intersecting steel bar extends outward from the first transverse steel bar into the first panel, and the second intersecting branch of the intersecting steel bar extends outward from the second transverse steel bar into the second panel. The first transverse steel bar and the second transverse steel bar are located between the first panel and the second panel. The shell plate is provided with a window, and the inner ring of the functional core layer is exposed through the window; the thickness of the filling space from the inner ring to the outer ring of the filling space between the first panel and the second panel gradually increases and then decreases; at the window position, a wooden block for window installation is pre-embedded between the first panel and the second panel.

2. The combined energy-saving prefabricated exterior wall panel according to claim 1, characterized in that, The first transverse reinforcing bar is located inside the first panel, and the second transverse reinforcing bar is located inside the second panel.

3. The combined energy-saving prefabricated exterior wall panel according to any one of claims 1-2, characterized in that, The functional core layer is at least one of the following: a thermal insulation layer, a fireproof layer, and a sound insulation layer.

4. A method for preparing the combined energy-saving prefabricated exterior wall panel according to any one of claims 1-3, characterized in that, include: Pour the bottom layer of concrete into the wall panel mold to form the first panel; A functional core layer is placed on the bottom concrete, with the two sides of the functional core layer abutting against the two sides of the wall panel mold. A first pouring space is reserved at the top of the functional core layer and the top of the wall panel mold, and a second pouring space is reserved at the bottom of the functional core layer and the bottom of the wall panel mold. Top layer concrete is poured into the wall panel mold to form the top plate in the first pouring space, the bottom layer in the second pouring space, and the second panel is formed on the top plate, the functional core layer, and the bottom layer.

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