A reinforced wireless signal resistant aerated concrete wallboard and method of processing the same

Abstract

The application discloses an anti-corrosion aerated concrete wallboard for enhancing wireless signal, which comprises a base plate, a closed cavity formed in the base plate, polyurethane foaming heat-insulating material filled in the cavity, a plurality of connecting columns formed in the cavity, an organic heat-insulating waterproof layer arranged on the inner wall of the cavity and the connecting columns, an FRP net cage arranged in the base plate, the FRP net cage comprising two FRP meshes, a plurality of FRP connecting sheets and a plurality of FRP short bars, the plurality of FRP connecting sheets being fixedly connected to the upper and lower ends of the two FRP meshes, and the plurality of FRP short bars being fixedly connected between the two FRP meshes. The application uses the FRP net cage to replace the steel mesh cage, and the steel mesh corrosion is not needed, so that the hidden danger of wallboard damage caused by steel rust is solved, the building is not a steel cage any more, the shielding effect is eliminated, the radio signal shielding problem is solved, and the increase of the equivalent heat conductivity coefficient of the wallboard and the decrease of the heat-insulating performance caused by the steel mesh are solved.

Description

Technical Field

[0001] This invention relates to the fields of building assembly and thermal insulation technology, and more specifically to a corrosion-resistant aerated concrete wall panel that enhances wireless signals and its processing method. Background Technology

[0002] Autoclaved aerated concrete (AAC) wall panels have been widely used in China since their introduction from abroad. Their excellent thermal insulation performance has been particularly well-received in integrated insulation applications. However, as insulation requirements have increased, their disadvantages have become increasingly apparent. The reinforcing mesh within the wall panels is crucial for ensuring safety during construction and use. However, the use of this mesh negatively impacts the wall panels' insulation function. Furthermore, because AAC is a porous material, moisture and harmful substances in the air can cause corrosion of the reinforcing mesh, ultimately damaging the wall panels. Although anti-corrosion layers exist, the complex manufacturing process of these coatings makes it difficult to guarantee their quality. Additionally, the presence of double-layered reinforcing mesh in the wall panels creates a steel cage, potentially blocking wireless signal transmission. Using materials superior to steel reinforcement, such as FRP (fiber-reinforced polymer), which are composites of inorganic fibers and resin, to create organic mesh sheets and then construct mesh cages instead of steel reinforcement cages eliminates the need for steel reinforcement corrosion protection, thus preventing damage caused by rust. Secondly, replacing steel reinforcement with FRP mesh eliminates the shielding effect, preventing the building from becoming a steel cage and resolving the problem of radio signal shielding. Third, it solves the problem of increased equivalent thermal conductivity and reduced thermal insulation performance of wall panels caused by steel mesh.

[0003] Therefore, how to provide a corrosion-resistant aerated concrete wall panel that enhances wireless signals and its processing method is one of the technical problems that urgently need to be solved in this field. Summary of the Invention

[0004] In view of this, the present invention provides a corrosion-resistant aerated concrete wall panel for enhancing wireless signals and a method for processing the same. The purpose is to address the aforementioned shortcomings.

[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0006] A corrosion-resistant aerated concrete wall panel for enhancing wireless signals includes a base plate, wherein a closed cavity is formed inside the base plate and the cavity is filled with polyurethane insulation material; multiple connecting columns are also formed inside the cavity; and an organic thermal insulation and waterproof layer is provided on the inner wall of the cavity and the multiple connecting columns.

[0007] An FRP mesh cage is also provided inside the base plate; the FRP mesh cage includes two FRP mesh panels, several FRP connecting pieces, and several FRP short ribs, and several FRP connecting pieces are fixedly connected to the upper and lower ends of the two FRP mesh panels; several FRP short ribs are all fixedly connected between the two FRP mesh panels.

[0008] Preferably, the organic thermal insulation and waterproof layer is a coating formed by melting organic hot-melt substances.

[0009] Preferably, the organic hot melt material has multiple pre-drilled holes on its sidewall, which can form a connecting column that is integral with the base plate during casting.

[0010] Preferably, each of the FRP short ribs may be perpendicular to the two FRP meshes; or, obliquely intersecting the two FRP meshes.

[0011] Preferably, the two FRP mesh sheets, the several FRP connecting pieces, and the several FRP short ribs are integrally formed.

[0012] Preferably, the FRP mesh is coated with a special steam-curing anti-corrosion coating.

[0013] Preferably, each of the FRP connecting pieces has a pre-drilled insertion hole in the middle that is compatible with the steel rod.

[0014] Preferably, the cavity is one of a rectangle, a convex circle, a circle, or an irregular shape.

[0015] Preferably, the plurality of connecting columns are integrally cast with the base plate.

[0016] Preferably, the inorganic fibers in the FRP can be made of glass fiber, carbon fiber, basalt fiber, etc.

[0017] Preferably, the FRP connecting piece is made of FRP material, plastic material, or steel.

[0018] Meanwhile, the present invention also provides a method for processing corrosion-resistant aerated concrete wall panels that enhance wireless signals, comprising the following steps:

[0019] 1) FRP wire mesh cages are made of FRP material and are kept for later use; and insertion holes are made in the middle of the FRP connecting piece along the width of the FRP wire mesh cage for inserting and removing steel rods.

[0020] 2) According to the design requirements, the organic hot-melt material is made into a through hole along the thickness direction that matches the insertion hole by hot melting or mechanical methods;

[0021] 3) Place the prepared organic hot melt material into the FRP mesh cage and fix it in place;

[0022] 4) Steel fibers are used to pass through the insertion holes and the through holes, with their upper and lower ends passing through the middle part of the FRP connecting piece and fixed in place, thereby assembling and fixing the FRP mesh cage onto the steel rod frame;

[0023] 5) Slurry preparation: Grind the siliceous material with water and set aside; Gypsum preparation: It can be ground together with the siliceous material or added separately; Lime powder preparation: Grind the lime powder and set aside; Add aluminum powder to water to make an aluminum powder suspension and set aside.

[0024] 6) Pouring: Pump the casting raw materials prepared in step 5) into the casting tank, add the lime powder and cement prepared in step 5) in sequence, and stir for 2 to 8 minutes. After the slurry temperature reaches 40 to 50°, add the aluminum powder suspension, stir for 20 to 100 seconds, and then pour it into the mold for preparing the autoclaved aerated concrete slab.

[0025] 7) Use a special tool to press down the organic hot melt material or FRP mesh on the upper side to prevent it from floating and damaging the concrete slab.

[0026] 8) Place the steel rod frame obtained in step 4) into the mold that was just poured in step 6), and then cure it. The curing temperature is 30-60℃ and the curing time is 3-3.5h. After the strength of the blank reaches a certain level, pull out the rod to obtain the corrosion-resistant aerated concrete wall panel blank that enhances wireless signals.

[0027] 9) The corrosion-resistant aerated concrete wall panel blank with enhanced wireless signal obtained in step 8) is transported to the cutting machine for six-sided cutting;

[0028] 10) Place the corrosion-resistant aerated concrete wall panel preform with enhanced wireless signal processed in step 9) into an autoclave and vacuum it. Then add saturated steam to make the pressure inside the autoclave 1.0-1.2 MPa and the temperature 170-200℃. Cure under constant pressure for 6-8 hours. The organic hot melt material melts to form a closed cavity, and an organic heat insulation and waterproof layer is formed on the inner wall of the cavity and the outer wall of multiple connecting columns. After hydration reaction, the corrosion-resistant aerated concrete wall panel preform with enhanced wireless signal becomes a corrosion-resistant aerated concrete wall panel product with enhanced wireless signal.

[0029] 11) After curing and venting, open the autoclave door and pull out the corrosion-resistant aerated concrete wall panel that enhances wireless signal in the final product, and break the panel apart.

[0030] Preferably, the casting material in step 6) comprises the following components by weight: 50%–75% siliceous material, 12%–18% lime powder, 12%–24% cement, 2%–10% gypsum, and 0.06%–0.12% aluminum powder (paste).

[0031] Preferably, the organic hot-melt material is placed inside the FRP mesh cage; or, the organic hot-melt material extends outside the FRP mesh cage.

[0032] The present invention achieves the following technical effects compared to the prior art:

[0033] This invention utilizes a superior material to reinforcing steel, composed of inorganic fibers such as FRP and resin, to create an organic mesh. This FRP mesh cage replaces the traditional steel mesh cage, eliminating the need for steel corrosion protection and resolving the potential damage to the wall panels caused by steel rust. Secondly, by replacing steel mesh with FRP mesh, the building is no longer a steel cage, eliminating the shielding effect and solving the problem of radio signal shielding. Thirdly, it addresses the increased equivalent thermal conductivity and reduced insulation performance of the wall panels caused by steel mesh. Furthermore, by melting the organic hot-melt material inside the concrete slab, multiple sealed cavities are formed, creating an air layer. To address the heat convection within this large air layer, polyurethane insulation material is injected into the cavities, significantly improving insulation performance. Moreover, the hot-melt material adheres to the inner surface of the cavities, increasing the surface strength of the aerated concrete and further enhancing the bond strength between the polyurethane insulation material and the wall panel, thus improving the overall performance of the wall panel. Furthermore, by injecting polyurethane into the cavity, the exchange of moisture is blocked; the presence of the connecting column will carry the moisture accumulated on the surface of the polyurethane layer to the surface of the wall panel, thus solving the problem of exterior wall paint peeling caused by moisture content in the sandwich insulation board. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the structure of a corrosion-resistant aerated concrete wall panel for enhancing wireless signals according to the present invention.

[0035] Figure 2 This is a schematic diagram of the processing framework for a corrosion-resistant aerated concrete wall panel that enhances wireless signals according to the present invention.

[0036] In the diagram: 1. Baseboard; 2. FRP mesh cage; 21. FRP mesh sheet; 22. FRP connecting piece; 23. Insertion hole; 24. FRP short rib; 3. Cavity; 4. Organic hot melt material; 41. Reserved hole; 5. Organic thermal insulation and waterproof layer; 6. Connecting column. Detailed Implementation

[0037] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] Example

[0039] Reference Figure 1 The diagram shows a corrosion-resistant aerated concrete wall panel for enhancing wireless signals, comprising a base plate 1, wherein a closed cavity 3 is formed inside the base plate 1, and the cavity 3 is filled with polyurethane insulation material; a plurality of connecting columns 6 are also formed inside the cavity 3; and an organic thermal insulation and waterproof layer 5 is provided on the inner wall of the cavity 3 and the plurality of connecting columns 6.

[0040] An FRP mesh cage 2 is also provided inside the base plate 1; the FRP mesh cage 2 includes two FRP mesh panels 21, several FRP connecting pieces 22 and several FRP short ribs 24, and several FRP connecting pieces 22 are fixedly connected to the upper and lower ends of the two FRP mesh panels 21; several FRP short ribs 24 are all fixedly connected between the two FRP mesh panels 21.

[0041] In this embodiment, the organic thermal insulation and waterproof layer 5 is a coating formed by melting the organic hot-melt substance 4.

[0042] In this embodiment, the organic hot melt material 4 has multiple reserved holes 41 on its side wall, which can form a connecting column 6 integral with the base plate 1 during casting.

[0043] In this embodiment, each of the FRP short ribs 24 can be perpendicular to the two FRP meshes 21; or, obliquely intersecting the two FRP meshes 21.

[0044] In this embodiment, the two FRP mesh sheets 21, the several FRP connecting pieces 22, and the several FRP short ribs 24 are integrally formed.

[0045] In this embodiment, each FRP connecting piece 22 has a pre-drilled insertion hole 23 in the middle that is compatible with the steel rod.

[0046] In this embodiment, the cavity 3 can be one or more of a rectangular, convex, circular, or irregular shape.

[0047] In this embodiment, the multiple connecting columns 6 are integrally cast with the base plate 1.

[0048] In this embodiment, the inorganic fibers in the FRP material used in the FRP mesh cage 2 can be made of glass fiber, carbon fiber, or basalt fiber.

[0049] In this embodiment, the FRP mesh 21 is coated with a special steam curing anti-corrosion coating.

[0050] In some embodiments, the number of cavities 3 and FRP connecting pieces can be adjusted according to actual needs.

[0051] In some embodiments, the organic hot melt material 4 is placed inside the FRP mesh cage 2; or, the organic hot melt material 4 extends outside the FRP mesh cage 2.

[0052] In other embodiments, the FRP connector 22 may be made of FRP material or plastic material, or a steel connector.

[0053] In some other embodiments, the connecting column 6 and the FRP short rib 24 may be provided, or neither may be provided.

[0054] Example 2

[0055] A method for processing corrosion-resistant aerated concrete wall panels that enhance wireless signals includes the following steps:

[0056] 1) FRP wire mesh cage 2 is made of FRP material and is used for backup; and insertion holes 23 are opened in the middle of the FRP connecting piece along the width direction of FRP wire mesh cage 2 for inserting and removing steel rods.

[0057] 2) The organic hot-melt material 4 is made into a through hole along the thickness direction according to the design requirements by hot melting or mechanical methods, which is compatible with the insertion hole 23;

[0058] 3) Place the prepared organic hot melt material 4 into the FRP mesh cage 2 and fix it in place;

[0059] 4) Steel fibers are used to pass through the insertion hole 23 and the through hole, and their upper and lower ends pass through the middle part of the FRP connecting piece 22 and are fixed, thereby assembling and fixing the FRP mesh cage 2 onto the steel rod frame;

[0060] 5) Slurry preparation: Grind the siliceous material with water and set aside; Gypsum preparation: It can be ground together with the siliceous material or added separately; Lime powder preparation: Grind the lime powder and set aside; Add aluminum powder to water to make an aluminum powder suspension and set aside.

[0061] 6) Pouring: Pump the casting raw materials prepared in step 5) into the casting tank, add the lime powder and cement prepared in step 5) in sequence, and stir for 2 to 8 minutes. After the slurry temperature reaches 40 to 50°, add the aluminum powder suspension, stir for 20 to 100 seconds, and then pour it into the mold for preparing the autoclaved aerated concrete slab.

[0062] 7) Use a special tool to press down the organic hot melt material 4 or FRP mesh cage 2 on the upper side to prevent it from floating up and damaging the concrete slab.

[0063] 8) Place the steel rod frame obtained in step 4) into the mold that was just poured in step 6), and then cure it. The curing temperature is 30-60℃ and the curing time is 3-3.5h. After the strength of the blank reaches a certain level, pull out the rod to obtain the corrosion-resistant aerated concrete wall panel blank that enhances wireless signals.

[0064] 9) The corrosion-resistant aerated concrete wall panel blank with enhanced wireless signal obtained in step 8) is transported to the cutting machine for six-sided cutting;

[0065] 10) Place the corrosion-resistant aerated concrete wall panel preform with enhanced wireless signal processed in step 9) into an autoclave and vacuum it. Then add saturated steam to make the pressure inside the autoclave 1.0-1.2 MPa and the temperature 170-200℃. Cure under constant pressure for 6-8 hours. The organic hot melt material 4 melts to form a closed cavity 3, and an organic thermal insulation and waterproof layer 5 is formed on the inner wall of the cavity 3 and the outer wall of multiple connecting columns 6. After hydration reaction, the corrosion-resistant aerated concrete wall panel preform with enhanced wireless signal forms a corrosion-resistant aerated concrete wall panel product with enhanced wireless signal.

[0066] 11) After curing and venting, open the autoclave door and pull out the corrosion-resistant aerated concrete wall panel that enhances wireless signal in the final product, and break the panel apart.

[0067] In this embodiment, the casting material in step 6) includes the following components by weight: 50% to 75% siliceous material, 12% to 18% lime powder, 12% to 24% cement, 2% to 10% gypsum, and 0.06% to 0.12% aluminum powder (paste).

[0068] In this embodiment, the organic hot melt material 4 is placed inside the FRP mesh cage 2; or, the organic hot melt material 4 extends outside the FRP mesh cage 2.

[0069] This invention utilizes a superior material to reinforcing steel, composed of inorganic fibers such as FRP and resin, to create an organic mesh. This FRP mesh cage replaces the traditional steel mesh cage, eliminating the need for steel corrosion protection and resolving the potential damage to the wall panels caused by steel rust. Secondly, by replacing steel mesh with FRP mesh, the building is no longer a steel cage, eliminating the shielding effect and solving the problem of radio signal shielding. Thirdly, it addresses the increased equivalent thermal conductivity and reduced insulation performance of the wall panels caused by steel mesh. Furthermore, by melting the organic hot-melt material inside the concrete slab, multiple sealed cavities are formed, creating an air layer. To address the heat convection within this large air layer, polyurethane insulation material is injected into the cavities, significantly improving insulation performance. Moreover, the hot-melt material adheres to the inner surface of the cavities, increasing the surface strength of the aerated concrete and further enhancing the bond strength between the polyurethane insulation material and the wall panel, thus improving the overall performance of the wall panel. Furthermore, by injecting polyurethane into the cavity, the exchange of moisture is blocked; the presence of the connecting column will carry the moisture accumulated on the surface of the polyurethane layer to the surface of the wall panel, thus solving the problem of exterior wall paint peeling caused by moisture content in the sandwich insulation board.

[0070] The above description is merely a preferred embodiment of the present invention and does not constitute any limitation on the technical scope of the present invention. Therefore, any minor 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 corrosion-resistant aerated concrete wall panel for enhancing wireless signals, comprising a base panel (1), characterized in that, The base plate (1) has a closed cavity (3) inside, and the cavity (3) is filled with polyurethane insulation material; multiple connecting columns (6) are also formed inside the cavity (3); and an organic insulation and waterproof layer (5) is provided on the inner wall of the cavity (3) and the multiple connecting columns (6). An FRP mesh cage (2) is also provided inside the base plate (1); the FRP mesh cage (2) includes two FRP mesh panels (21), several FRP connecting pieces (22) and several FRP short ribs (24), and several FRP connecting pieces (22) are fixedly connected to the upper and lower ends of the two FRP mesh panels (21); several FRP short ribs (24) are fixedly connected between the two FRP mesh panels (21); The organic thermal insulation and waterproof layer (5) is a coating formed by melting organic hot melt material (4); The organic hot melt material (4) has multiple reserved holes (41) on its side wall, which can form a connecting column (6) that is integral with the base plate (1) during casting. The two FRP mesh sheets (21), the several FRP connecting pieces (22), and the several FRP short ribs (24) are integrally formed; Each of the FRP connecting pieces (22) has a pre-drilled insertion hole (23) in the middle that is compatible with the steel rod.

2. The corrosion-resistant aerated concrete wall panel for enhancing wireless signals according to claim 1, characterized in that, Each of the FRP short ribs (24) is perpendicular to the two FRP meshes (21); or, obliquely intersecting the two FRP meshes (21).

3. The corrosion-resistant aerated concrete wall panel for enhancing wireless signals according to claim 1, characterized in that, The cavity (3) is one of a rectangle, a convex circle, a circle, or an irregular shape.

4. The corrosion-resistant aerated concrete wall panel for enhancing wireless signals according to claim 1, characterized in that, Multiple connecting columns (6) are integrally cast with the base plate (1).

5. A method for processing corrosion-resistant aerated concrete wall panels for enhancing wireless signals as described in any one of claims 1-4, characterized in that, Includes the following steps: 1) FRP wire mesh cage (2) is made of FRP material and is ready for use; and insertion holes (23) are opened in the middle of the FRP connecting piece along the width direction of the FRP wire mesh cage (2) for inserting and removing steel rods; 2) The organic hot melt material (4) is made into through holes and reserved holes (41) along the thickness direction according to the design requirements by hot melting or mechanical methods. 3) Place the prepared organic hot melt material (4) into the FRP mesh cage (2) and fix it in place; 4) Steel fibers are used to pass through the insertion hole (23) and the through hole, and their upper and lower ends pass through the middle part of the FRP connecting piece (22) and are fixed, so as to assemble and fix the FRP mesh cage (2) on the steel rod frame; 5) Slurry preparation: Grind the siliceous material with water and set aside; Gypsum preparation: It can be ground together with the siliceous material or added separately; Lime powder preparation: Grind the lime powder and set aside; Add aluminum powder to water to make an aluminum powder suspension and set aside. 6) Pouring: Pump the casting raw materials prepared in step 5) into the casting tank, add the lime powder and cement prepared in step 5) in sequence, and stir for 2 to 8 minutes. After the slurry temperature reaches 40 to 50°, add the aluminum powder suspension, stir for 20 to 100 seconds, and then pour it into the mold for preparing the autoclaved aerated concrete slab. 7) Use a special tool to press down the organic hot melt material (4) or FRP mesh cage (2) on the upper side to prevent it from floating up and damaging the concrete slab. 8) Place the steel rod frame obtained in step 4) into the mold that was just poured in step 6), and then cure it. The curing temperature is 30-60℃ and the curing time is 3-3.5h. After the strength of the blank reaches a certain level, pull out the rod to obtain the corrosion-resistant aerated concrete wall panel blank that enhances wireless signals. 9) The corrosion-resistant aerated concrete wall panel blank with enhanced wireless signal obtained in step 8) is transported to the cutting machine for six-sided cutting; 10) Place the corrosion-resistant aerated concrete wall panel preform with enhanced wireless signal processed in step 9) into an autoclave and vacuum it. Then add saturated steam to make the pressure inside the autoclave 1.0-1.2 MPa and the temperature 170-200℃. Cure under constant pressure for 6-8 hours. The organic hot melt material (4) melts to form a closed cavity (3), and an organic heat insulation and waterproof layer (5) is formed on the inner wall of the cavity (3) and the outer wall of multiple connecting columns (6). The corrosion-resistant aerated concrete wall panel preform with enhanced wireless signal is formed into a corrosion-resistant aerated concrete wall panel product with enhanced wireless signal after hydration reaction. 11) After curing and venting, open the autoclave door and pull out the corrosion-resistant aerated concrete wall panel that enhances wireless signal in the final product, and break the panel apart.

6. The processing method of a corrosion-resistant aerated concrete wall panel for enhancing wireless signals according to claim 5, characterized in that, The casting material in step 6) includes the following components by weight: 50%–75% siliceous material, 12%–18% lime powder, 12%–24% cement, 2%–10% gypsum, and 0.06%–0.12% aluminum powder (paste).

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